BUDGET GUIDELINES

Recommended on original equipment manufacturer's parts

Station/Equipment

Parts

Replacement Cycle

FFB cages

Replacement cycle based on table below:

RECEPTION
Cages

Cap. Cages

Tippler
Hoist
25% max
20% max
2.75 tons
25% max
20% max
3.75 tons
25% max
20% max
5.00 tons
6 yrs
17% max
8.00 tons
7 yrs
14% max
10.00 tons
8 yrs
13% max
Example: No of cages for 60 MT/hr = 6 hrs x rated throughput = 6 x 60
= 360 tons / 5 tons/cage = 72 cages ---> 20% is 72/5 = 15 cages
For new mills, after year 2000, replacement to start from 5th year (for 5 ton cages with tipplers)
For old mills before year 2000, using crane, replacement start from 4th year
2.50 tons

Capstan

cycle

start

5 yrs
5 yrs
5 yrs

4th
4th
4th
5th
5th
6th

Wire rope

0.008 Meters /ton FFB (3.75 ton cage)

0.01 Meters/ton FFB (5 ton cage)
(specification of wirerope to be provided by EPDV and approved by MCMD)

Door packing
Pieces packing per door per year =

1 door-packing every 12000 tons ffb (based on door with stainless steel insert)
(original from the door manufacturer & minimum EPDM)
(Budgetted FFB/12000/no. of doors)

Solenoid valves

1 Solenoid valve for air line, every 30000 tons ffb

STERILIZATION
Sterilizers

THRESHING
Bunch conveyors
Chain - 6 inch x 30000 lb breaking load chain
Sprocket

Horizontal
15000
7500

Inclined
10000
5000

Hoist

Conveyor below thresher

Thresher

Endless chain
Sprockets
Wirerope

90000 tons FFB/ set chain

45000 tons FFB/ set sprocket
0.001 meter/ ton FFB
(spare part from MHE/DEMAG)

Scroll
Liner

12000 hours
12000 hours

Flat bars

750000 tons ffb/thresher

EMPTY BUNCH TREATMENT

EB horizontal conveyor

Chain - 4 inch x 15000lbs breaking load

Sprocket - 2 sets

15000 hours
7500 hours

EB inclined conveyor

Chain - 4 inch x 15000 lbs. breaking load

Sprocket - 2 sets

10000 hours
5000 hours

Bunch crusher elevator

Chain - 6 inch x 30000 lbs breaking load

Sprockets - 2 sets

18000 hours
9000 hours

PRESSING
Fruit elevator

Chain - 6 inch x 30000 lbs breaking load

Sprockets - 2 sets
Buckets

10000 hours
5000 hours
5% of total/year/unit of elevator

Fruit Distributing conveyor,

bottom cross conveyor
& top cross conveyor
Recycling Fruit conveyor

Scroll
Liner

12000 hours
12000 hours

Digester

Stirring arms per unit

Expeller arms per unit
Liners, baffles & bottom plate per unit
Shaft per unit

3000 hours
3000 hours
7500 hours

(Manganese Steel Hardness HRC 55)

30000 hours (shaft to be wrapped with stainless steel)

(Carbon content of shaft to be 0.35% to 0.45% )

Screw Press
Worm screws - 1000 hours
(comply to manufacturer's drawing)
Press cage - 2000 hours
Adjusting cone - 3000 hours
Lenghtening shaft = 3000 hours
Strainer plate - 10000 hours
Main shaft - 1/4 set per year per press running
Spur gear - 1/4 set per year per press running
Bushing for lenghtening shaft - 400 hours/set
Spectacle plate - 1 pc per press / year
Extension shaft - 1 set per year
Cake Breaker Conveyor

P9
10000
20000
30000
30000
100000
50000
50000
4000
25000
25000

P15
P20
15000 20000 tons ffb/press/change
30000
45000
45000
150000
75000
75000
6000
38000
38000

40000 tons ffb/press/change

60000 tons ffb/press/change
60000 tons ffb/press/change
200000 tons ffb/press/change
100000 tons ffb/press/change
100000 tons ffb/press/change
8000 tons ffb/press/change
50000 tons ffb/press/change
50000 tons ffb/press/change

Scroll
Liner

7500 hours
7500 hours

Screens
No of screens per year =

2 screens per 150000 tons ffb

(Budgetted FFB x 2/150000)

Hycar gasket
No of gaskets per year =

3 hycar gaskets per 150000 tons ffb

(Budgetted FFB x 3/150000)

Clamp rings (set)

1/2 set per vibrating screen per year

Solids conveyor

Scroll
Liner

2500 hours
5000 hours

Sand Cyclone

Ceramic cone

2 piece per unit per year

Sludge Vibrating Screen

( 2 units Single Deck)

Screen
No of screens per year =

1 screen per 75000 tons ffb

(Budgetted FFB/75000)

Hycar gasket
No of gaskets per year =

2 hycar gasket per 150000 tons ffb

(Budgetted FFB x 2/150000)

Clamp ring

1/2 set per vibrating screen per year

CLARIFICATION
Crude oil vibrating screen
(3 units double deck)

Sludge Centrifuge

Nozzles
Nozzle holder
Cap nut
Lock nut
Wearing strip
Splash guard

2500 hours/nozzle
5000 hours/ pc
2500 hours/pc
5000 hours/pc
7500 hours/set
15000 hours/set

Decanter

Bearing
Scroll Reconditioning
Drive belt

2 pcs/unit/5000 hours
20000 hours
1 set/unit/5000 hours

Rotor bar

600 hours/set/unit
Spec sama dengan Region Kalsel. Bahan HQ705 Hardened
1000 hours/unit
600 hours/set/unit
Spec sama dengan Region Kalsel.
1000 hours/unit

NUT & KERNEL

Ripple mill

Ripple plate
Stator bar
Rotor plates
Elevators
Chain - 4 inch x 15000 lbs breaking load

Cracked Mix conveyor

Wet --> 4000 hours

Dry --> 10000 hours

Sprockets

Wet --> 2000 hours

Dry --> 5000 hours

Buckets

Wet --> 10% of total number buckets/year

(Beban tidak terlalu berat dan keausan tidak signifikan)
Dry --> 5% of total number buckets/year

Usulan baru dengan mempertimbangkan kondisi dan fungsi dari masing-masing conveyor:
Scroll
10000 hours
Liner
20000 hours

Kernel Distributing conveyor

Scroll
Liner

15000 hours
30000 hours

Dry Kernel Conveyor

Scroll
Liner

30000 hours
30000 hours

Wet shell conveyor

Scroll
Liner

6000 hours
6000 hours

Ketebalan dan material sama antara

scroll dengan liner, sehingga keausan
sama

Claybath

Screen

(2 units Double Deck)

Hycar gasket
Clamping ring
CaCO3

Kernel silo

8 screens per 300000 tons ffb

(Aktual sekarang, semua PSM over-spent)
8 pcs hycar gasket per 300000 tons ffb
1 set clamping ring per 300000 tons ffb
1 kg/ton TBS (for 100% inti)
1.2 kg/ton TBS if <50% plasma + TBS luar to total
1.3 kg/ ton TBS if >50% plasma + TBS luar to total

Heaters (8 units)
Diganti mulai dari tahun ke-5 dengan catatan
design pemipaan dan steam trapping dan
instalasi lain yang sesuai dengan "good
engineering practice" (useful life at 4 years)
1 pc per 150000 tons FFB

Airlock

ID fan

Dust cyclone

Usulan baru dengan mempertimbangkan kondisi dan fungsi dari masing-masing airlock/rotary feeder:
Fiber cyclone airlock
10000 hours
Nut Cyclone air lock
10000 hours
Umpan Ripple Mill
20000 hours
LTDS Cyclone air lock
5000 hours
Kernel Silo
25000 hours
Impeller

Cyclones

1 unit per 15000 hours per boiler (catatan : rekondisi hanya 1x pada
10000 jam, dan hasil rekondisi dioperasikan selama 5000jam)
1 set/5000 jam/unit boiler

(spare part beli dari manufacturer)

(white cast iron - chilled iron casting min 55 HRB - Mechmar recommendation)

(min 50 HRC to be cross checked)

Softner / Demin plant

Resins

Boiler feed water pump

5% of total volume of resin per unit / year

Purchase 1 unit/5000 hours/boiler
Justification: repair cost is above 60% of new pump

(Put on hold the decision to purchase 1 unit/5000 hours/boiler till prices of

new pumps confirmed and approved by SMD Ops. Refer to previous decision of

overhaul 1 unit/5000 hours/boiler till approval given for new pumps)

Fuel Conveyor

Scroll
Liners

15000 hours
15000 hours

WATER SUPPLY
Boiler

0.65 m3/ton TBS

(excluding non-processing hours)
(Catatan: Perhitungan tambahan untuk pabrik yang ada KCP)

Regeneration

Softener

0.05 m3/Ton TBS

Deminplant
0.1 m3/ton TBS

Dilution

0.25 m3/Ton TBS (budget OER)

Budget OER minus 0.1m3/ton TBS

(2/3rd of 15% condensate to FFB for dilution)

Cleaning

0.05 m3/Ton TBS

Domestic

Based on SMG standard & actual number of units

POWER SUPPLY
Mill:
Processing
Water supply & effluent
Domestic
Engine running account
Requirement :
1. Processing :
2. Domestic :
3. Maintenance
T o t a l : KWH (A)

(kwh/ton FFB)
(kwh/ton FFB)

80 TPH
60 TPH
45 TPH
30 TPH
15 TPH
14.5
15
17.5
18.5
22
1.5
1.5
1.5
1.5
1.5
Based on SMG standard & actual number of units

Power consumption (kwh/ton FFB) x annual FFB ====> e.g. 17.5 kwh x 318,174 = 5,566,8045
Based on the SMG standard & actual number of units
12 hours x 70 kw/hour x total number of Sundays/year

Turbine :
1. Turbine running hours /day (minus hours from item 2 & 3 below) x no. of processing days/year x turbine power output*
2. 0.25 hours x jam olah/ 4 jam x no.of processing days/year x turbine power output* x 0.8
3. Start / stop - 2 hours x no of processing days/year x turbine power output* x 0.7
T o t a l : KWH (B)
Diesel
(A) - (B)
Solar 3,5 kWh/liter
* Note :
1. If actual load > 90% of rated turbine output, then use 90% of the rated turbine output for calculation.
2. If actual load is less then 90%, use actual load for calculation
Genset
Alternators (diesel & turbine)

Write-off at 40,000 hours

Decision for overhauling alternator

5 years or 20000 hrs. Deciding factor is the insulation

resistance: (i) if resistance is <2 Mohms,(ii) if insulation
resistance over 2 consecutive measurements drop of
more than 1 Mohm, (iii) Polarization index (PI) <2.
Frequency of insulation resistance testing (Megger Test)
shall be carried out 3 monthly. If insulation resistance
falls below 5 Mohms, Megger Test shall be carried out
fortnightly.

BOILER CHEMICALS
Demin Plant:
Internal:

Nalco
Drew
Kastraco

Interchemical

Depending on water condition

Rp 400 / ton FFB
To be reviewed after data in SAP is complete
Rp 400 / ton FFB
Rp 400/ ton FFB

GENERAL CONSUMABLES
-

Angkong
per 1000 ton FFB
Spt boot plastik
karyawan process kecuali workshop
Safety shoes
workshop cicilan 10 bln
Pakaian Kerja
Masker kain
Masker plastik (boiler, kernel, wtp)
Earmuffler - powerstation
Earplug (kernel, steriliser)
Helmet - external
Helmet - internal (harness)
Instant mie
Selang lantai - plastik benang 1 inch
Kain Majun (warna-warni)
Genset - solar
Sarung tangan :
(I) Rebusan 4 operator
(ii) Boiler
4 operator
(iii) Loading ramp 4 operator
(iv) Clarification 2 operator
(v) threshing 2 operator
(vi) kamar mesin 2 operator

0.2
2 pcs/year
1 pcs/year PSM I tidak cicil
2 pcs/year
Tidak ada
3 pcs/year
1 pcs/year
2 pcs/year
1 pc every 3 years
1 pc/year
hanya jika jam kerja > 9 jam
1.5 mtr per 1000 ton FFB
0.8 kg per 1000 ton FFB
3.5 kwh per litre
3 pairs per worker per year