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Technical Specifications and Descriptions

AUTOMATED INDEXER SYSTEMS TECHNICAL DESCRIPTION

Raw material in the form of Fresh Fruit Bunches (FFB) arriving at the Palm Oil Mill (POM) in
lorry or in other modes of transport, are subsequently weighed and graded according to the
degree of ripeness typically, over-ripe, ripe and under-ripe. Fruit of various grades are sent
to the loading ramp preferably to designated areas according to the grade of fruit.

1. Loading Ramp Doors

FFB is discharged onto the loading ramp conveyor through hydraulically operated loading
ramp doors. The control of these doors should be via a remote control console (RCC-Station
1) housing a microprocessor capable of managing the various input/output signals to
activate solenoid operated directional valves to cause the remote up/down movement of
the loading ramp doors. CCTV cameras should be positioned at each loading ramp door to
feedback to the CCTVs monitor housed in the remote control console (RCC-Station 1).

The loading ramp doors shall be powered by a separate hydraulic power pack of which
meets the requirements of Item 23: Systems Requirements

2. Loading Ramp FFB Conveyor

Fruit discharged onto the loading ramp conveyor is conveyed to the fruit discharge
conveyor. The loading ramp scraper conveyor is driven by a twin hydraulic drive. The speed
of the drives, start/stop function and the emergency stop function should be controlled via
manual push button inputs to the microprocessor housed in the (RCC-Station 1).

The twin drive shall be powered by a separate power pack of which meets the requirements
of Item 23: Systems Requirements and the twin drive shall be directly coupled to
respective conveyor drive sprockets.

3. Fruit Discharge/Feeding Conveyor

Fruit delivered to the fruit discharge scraper conveyor is conveyed along the length of the
conveyor above the fruit cages assembled/positioned below respective fruit discharge chute
doors. The movement of the conveyor shall be via a twin hydraulic drive having on/off
emergency stop controlled via (RCC-Station 1).

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given to third parties.
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Technical Specifications and Descriptions
The twin drive shall be powered by a separate power pack of which meets the requirements
of Item 23: Systems Requirement and the twin drive shall be directly coupled to
respective conveyor drive sprockets.

The chute discharge doors are positioned beneath the scraper conveyor and facilitate the
discharge of fruit to the cages. The opening and closing of the fruit discharge doors shall be
hydraulically actuated via a hand operated directional valve ergonomically located at the
respective cage feeding point in a position that allows for the hand operation of the
directional valve based on the visual load status of the respective cage. The number of
hydraulically actuated discharge chute doors will depend on the number of discharge points
discharging fruit to cages positioned below. All but the last discharge chute shall be capable
of open/close except the last which shall remain open.

The chute doors actuators shall be powered by the same hydraulic power pack feeding the
twin drive.

4. Cages

Cages designed to accommodate a predetermined volume/mass of FFB shall be capable of


hands free latching/unlatching to facilitate the push/pull movement of a single cage or train
of cages away from the cage discharge conveyor by means of a hydraulically actuated
indexer which couples/uncouples from the cage to facilitate cage transfer.

5. FFB Discharge Station Hydraulic Indexer

The speed of cage transfer shall depend on the fixed stroking velocity of the indexer
actuator. The movement (distance/velocity) of the indexer actuator shall be set by the
proprietor to meet the desired FFB/Hour throughput capacity. The hydraulic indexer shall be
of robust mechanical construction adequately engineered to provide sufficient force to
overcome the inertia of a single cage or a train of cages from the discharge conveyor to the
Transfer Carriage. The movement of the indexer shall be remotely controlled via a remote
control console (RCC-Station 2) housing a micro-processor capable of managing the various
input/output signals to activate solenoid operated directional valves to cause the remote
stroking of the FFB discharge station hydraulic indexer. The start/stop function and the

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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Technical Specifications and Descriptions
emergency stop function should be controlled via manual push button input to the
microprocessor housed in the (RCC-Station 2).

The indexer shall be powered by a separate power pack and grade sensor of which meets
the requirements of Item 23: Systems Requirements

6. Dry Area Transfer Carriage on-load Indexer

The dry area transfer carriage indexer shall be located on the same floor axis as the FFB
discharge station indexer at the edge of the dry transfer carriage pit. The hydraulic indexer
shall be of robust mechanical construction adequately engineered to provide sufficient force
to overcome the inertia of a fully loaded single cage. The movement of the indexer shall be
remotely controlled via a remote control console (RCC-Station 2) housing a microprocessor
capable of managing the various input/output signals to activate solenoid operated
directional valves to cause the remote stroking of the dry area transfer carriage indexer. The
start/stop function and the emergency stop function should be controlled via manual push
button input to the microprocessor housed in the (RCC-Station 2)

The indexer shall be powered by a separate power pack and grade sensor of which meets
the requirements of Item 23: Systems Requirements

7. Dry Area Transfer Carriage

The transfer carriage shall be of robust mechanical construction and capable Dual Speed
Movement with Hi and Low speed ensuring high speed travel to a predetermined
destination and automatic slow down to ensure final and precise lane positioning.

The transfer carriage is powered by a hydraulic motor fed from an on board hydraulic power
pack of which meets the requirements of Item 23: Systems Requirements

The transfer carriage shall be capable of fixed position locking preferably via a spiral rotary
cam lock which positions the carriage relative to a locking lug set into the floor of the
transfer carriage pit.

The transfer carriage operation is remotely controlled from (RCC-Station 2) and shall be
capable of interlocking with upstream and downstream processes to prevent unsafe
operation.

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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Technical Specifications and Descriptions
The Transfer Carriage shall be integrated with a redundancy system override which provides
for the switching to manual operation as a backup system in the event of electronic
malfunction.

8. Dry Area Transfer Carriage off-load Indexer

The dry area transfer carriage off load indexer shall be located on the same floor axis as the
as the rail leading to the sterilizer. The hydraulic indexer shall be of robust mechanical
construction adequately engineered to provide sufficient force to overcome the inertia of a
fully loaded single cage or a train of cages. The movement of the indexer shall be remotely
controlled via a remote control console (RCC-Station 2) housing a microprocessor capable of
managing the various input/output signals to activate solenoid operated directional valves
to cause the remote stroking of the dry area off-load transfer carriage indexer.

The start/stop function and the emergency stop function should be controlled via manual
push button input to the microprocessor housed in the (RCC-Station 2)

The indexer shall be powered by the same hydraulic power pack and grade sensor
supporting the function of item 6 and item 8 of which meets the requirements of Item 23:
Systems Requirements

9. Sterilizer Drawbridge/Indexer in Dry Area

The entry of cages into the sterilizer shall be via a drawbridge capable of being hydraulically
lowered to a horizontal position from its vertical rest position. The drawbridge houses a
hydraulic indexer. The drawbridge and the indexer shall be of robust mechanical
construction adequately engineered to provide sufficient force to overcome the inertia of a
fully loaded single cage or a train of cages. The movement of the indexer shall be remotely
controlled via a remote control console (RCC-Station 3) housing a microprocessor capable of
managing the various input/output signals to activate solenoid operated directional valves
to cause the remote stroking of the drawbridge indexer and the raising and lowering of the
drawbridge.

RCC-Station 3 is also responsible for delivering the appropriate output signals to the
directional valves responsible for the actuation of the two hydraulic clutch locking ring

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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Technical Specifications and Descriptions
which secures the closure of the sterilizer door and a single hydraulic cylinder to facilitate
the opening and closing of the sterilizer door. RCC-Station 3 shall provide for the safety
interlocking of the drawbridge/door opening so as to prevent the premature opening of the
door before the sterilizer chamber pressure is returned to atmospheric pressure. RCC-
Station 3 shall house a microprocessor capable of managing the various input/output signals
to activate solenoid operated directional valves to cause the necessary hand-shaking
between the controller and indexing/drawbridge/sterilizer door opening/closing/manual
override for redundancy, start/stop/ emergency stop and safety interfacing. RCC-Station 3
and the hydraulic power pack servicing the various hydraulic actuators shall have the
capability of controlling up to three (3) sterilizer drawbridge/Indexer functions in the dry
area.

The draw bridge and drawbridge indexer shall be powered by a separate hydraulic power
pack and grade sensor of which meets the requirements of Item 23: Systems
Requirements

10. Control of the Sterilization Process

The sterilization process is highly dependent of the delivery and exhaust of steam at
predetermined intervals at predetermined pressure for a predetermined duration. It
therefore calls for a dual control/monitoring of both time and pressure.

The sterilization process shall be controlled using a windows based industrial grade
microprocessor control (RCC-Station 4), capable of handling the various I/O functions for
steam inlet and exhaust. It shall be fully programmable and contain several (pre-set
programmes to facilitate different time/pressure sequences for sterilizing various grades of
FFB. RCC-station 4 shall house the microprocessor and Visual Display Unit which is capable
of Manual Data Entry of inputs via a touch screen. Aside from facilitating the various
handshaking between input/outputs it shall provide a visual graphical display of the process
cycle based on pressure over time. The controller shall be capable of receiving a manual
input to switch from one predetermined sterilization cycle to another from a minimum of
four (4) pre-programmed process cycles.

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given to third parties.
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Technical Specifications and Descriptions
Each programme cycle must have the capability of handling a minimum of twenty (20)
programmable steps for managing the movement of steam into the sterilizer and
condensate from sterilization chamber. Furthermore, it shall have the capability of
managing the delivery of steam from the Back Pressure Receiver. The controller must be
capable of generating a printable graphical record of a sterilization cycle from historical data
store on file and have the capability of downloading stored data to conventional data
storage mediums and/or transfer of data via internet or cable transmission. RCC-Station 4
shall house and Emergency stop and safety interlocking function, with the capability of and
override to manual function of I/O in the event of redundancy.

The Sterilization Control Console shall be powered by Industrial PC with touch screen
functionality of which meets the requirements of Item 23: Systems Requirements

11. Back Pressure Receiver (BPR) Stabilizer

The Back Pressure Receiver (BPR) Stabilizer shall stabilize the flow of steam to ensure
consistent and sufficient steam is supplied for the milling process, especially sterilization
process. It is a requirement that the BPR Stabilizer has the capability of replenishing team
supplied to process as quickly as possible.

To achieve this it is required that the BPR Stabilizer is capable of receiving high pressure
steam via a direct steam line. This must be achieved by the incorporation of a modulating
valve that regulates the flow and pressure of boiler of steam at boiler pressure to the BPR.
The BPR stabilizer system ensures highly efficient steam usage there-by reducing steam
losses. It shall be integrated with item (10) Control of the Sterilization Process. Incorporated
within RCC-Station 4 shall be the capability of switching to manual operation of the BPR in
the event of redundancy

12. Sterilizer Drawbridge/Indexer in Wet Area


Sterilizer Drawbridge indexer shall function as described in section (9). It shall be controlled
via a separate RCC-Station 4 and the hydraulic power pack servicing the various hydraulic
actuators shall have the capability of controlling up to three (3) sterilizer
drawbridge/Indexer functions in the wet area.

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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Technical Specifications and Descriptions
The hydraulic actuators and bearings shall be adequately protected from the effects of
wet/hot/humid operating conditions. Said protection may include stainless steel cylinder
rods, stainless steel bearing housings and protective boots.

The indexer shall be powered by the hydraulic power pack and grade sensor supporting the
function of which meets the requirements of Item 23: Systems Requirements

13. Wet Area Transfer Carriage on-load Indexer

The wet area transfer carriage on-load indexer is as described in item (6). It shall be
controlled via a separate controller (RCC-Station 5) and hydraulic power pack having the
same technical description as that described in item (6)

The indexer shall be powered by the hydraulic power pack and grade sensor supporting the
function of which meets the requirements of Item 23: Systems Requirements

14. Wet Area Transfer Carriage

The wet area transfer carriage shall be is as described in item (8). The movement shall be
controlled via RCC-Station 5 and powered by the same hydraulic power pack servicing the
wet area transfer carriage on-load indexer. Adequate provisions must be made in the wet
area transfer carriage to ensure adequate protection of the moving parts including for
corrosion. The wet area transfer carriage shall include a stainless steel drip tray to capture
oil seeping form sterilized FFB

The transfer carriage shall be powered by the hydraulic power pack supporting the function
of which meets the requirements of Item 23: Systems Requirements

15. Wet Area Transfer Carriage off-load Indexer

The wet area transfer carriage indexer shall be as is described in item (8). The actuation of
same shall be controlled via RCC-Station 5 and powered by the same hydraulic power pack
servicing the wet area transfer carriage on-load index.

The indexer shall be powered by the hydraulic power pack and grade sensor supporting the
function of which meets the requirements of Item 23: Systems Requirements

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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Technical Specifications and Descriptions
16. Input to Tipper Indexer

The input to tipper hydraulic indexer shall be of robust mechanical construction adequately
engineered to provide sufficient force to overcome the inertia of a fully loaded single cage.
The movement of the indexer shall be remotely controlled via a remote control console
(RCC-Station 6) housing a microprocessor capable of managing the various input/output
signals to activate solenoid operated directional valves to cause the remote stroking of the
input to tipper indexer. The start/stop function and the emergency stop function should be
controlled via manual push button input to the microprocessor housed in the (RCC-Station
6). The actuation of the hydraulic indexer cylinder shall be powered by a separate hydraulic
power pack

The indexer shall be powered by the hydraulic power pack and grade sensor supporting the
function of which meets the requirements of Item 23: Systems Requirements

17. Tipper Rotation

The rotation of the cage tipper shall be via a hybrid hydraulic motor/gearbox capable of
variable speed control. The rotation of the tipper shall be remotely controlled via the
remote control console (RCC-Station 6) housing a microprocessor capable of managing the
various input/output signals to activate solenoid operated directional valves to cause the
remote rotation of the tipper. The start/stop function and the emergency stop function
should be controlled via manual push button input to the microprocessor housed in the
(RCC-Station 6). The actuation of the hydraulic indexer cylinder shall be powered by the
same hydraulic power pack supporting the input to tipper indexer. The controller housed in
RCC-Station 6 shall be capable of manual override in the event of redundancy and have the
capability of predetermined tipping rotation cycles including preprogrammed or input
caused pause, slowdown or stop/start.

18. Tipper Chute Door

At the bottom of the tipper chute there shall be a tipper chute door capable of automatic
opening/closing based on input signals received from the sterilized fruit scraper conveyor.
The RCC-Station 6 microprocessor shall be capable of receiving an input signal from the
sterilized fruit scraper conveyor which adequately assesses the load conditions on the
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given to third parties.
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Technical Specifications and Descriptions
sterilized fruit scraper conveyor and sending an output signal which controls the movement
of a directional valve which causes the actuation of the chute door. The same hydraulic
power pack powers the tipper chute door as that used to power the input to tipper indexer
item (15) and the tipper rotation item (16).

19. Output from Tipper Indexer

The output from tipper indexer shall be located on the same axis as the input to tipper
indexer. The output from tipper indexer shall be of robust mechanical construction and
adequately engineered to overcome the inertia of a single cage or a train of empty cages.
The movement of the indexer shall be remotely controlled via a remote control console
(RCC-Station 7) housing a microprocessor capable of managing the various input/output
signals to activate solenoid operated directional valves to cause the remote stroking of the
output from tipper indexer. The start/stop function and the emergency stop function should
be controlled via manual push button input to the microprocessor housed in the (RCC-
Station 7). The actuation of the hydraulic indexer cylinder shall be powered by a separate
hydraulic power pack.

The indexer shall be powered by the hydraulic power pack and grade sensor supporting the
function of which meets the requirements of Item 23: Systems Requirements

20. Buffer Indexer

The buffer indexer shall be on the same axis as the output from tipper indexer. It shall be of
robust mechanical construction and adequately engineered to overcome the inertia of a
single cage or a train of empty cages leading up to the fruit discharge/feeding conveyor. The
buffer indexer is powered by a separate power pack but receives the necessary signals to its
directional valves from RCC-Station 7 the function of which is described in item (18).

The indexer shall be powered by the hydraulic power pack and grade sensor supporting the
function of which meets the requirements of Item 23: Systems Requirements

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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Technical Specifications and Descriptions
21. Digester Level Control and Sterilized Fruit Conveyor / Tipper System Integration and
Synchronization

It is highly desirable that the movement of the sterilized fruit conveyor and the tipper
rotation are synchronized via a separate controller housed in (RCC-Station 8). The function
of the digester level control system is to dynamically measure the mass of fruit in any of the
digester at any point in time and this mass balance being detected by the load cells
mounted onto the digester. If the mass in any one or more of several digesters falls below or
rises above a predetermined level, the digester level control calls for the delivery of more
Sterilized Fruit from the tipper and the Sterilized Fruit Conveyor to be delivered via the
thresher into the digesters.

Conversely, if the digester/s exceeded a predetermined level, the delivery of fruit to the
digester shall be slowed. The movement of fruit into the digester/s from the digester feeder
conveyor shall be controlled via a digester feeding conveyor door opening at the base of the
digester feed conveyor to the top of the digester. The actuation of the gate hydraulic
cylinders is controlled via a separate hydraulic power pack and controller housed in (RCC-
Station 8). The start/stop function and the emergency stop function should be controlled via
manual push button input to the microprocessor housed in the (RCC-Station 8).

The sterilized fruit conveyor shall be of a scraper type and powered by a twin hydraulic
drive. The twin drive shall be powered by a separate power pack whose direction valves
receive input signals from (RCC-Station 8). The twin drive shall be directly coupled to
respective conveyor drive sprockets

22. Screw Press Control

The screw press shall include the closed loop control of a hydraulic actuator that applies a
controlled cone pressure to the MESOCARP mass exiting the screw press. The cone shall
exert a controlled and pressure comprised of a pulsating type reaction to avoid long stroking
of the cone cylinder due to slow reaction time. It is a requirement that the signal to adjust
the cone pressure originates from the screw press motor current.

The Screw Press control shall comprise a stand-alone hydraulic power pack that that has
been designed to deliver the desired pressure and flow of hydraulic fluid to the cone

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given to third parties.
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Technical Specifications and Descriptions
reaction cylinder via a fast reacting solenoid operated directional valve. The power pack
must function without the need of a separate heat exchanger. Furthermore the hydraulic
power pack shall comprise leak detection in the event of hydraulic oil overflow. The stand-
alone control shall be capable of operating the cone pressure within three distinct pressure
settings namely low medium and high. The control shall be capable of manual data input,
with multiple language capability. It should have the capability of recording historical trends
and provide for multi-level password access of data

The controller shall be capable of detecting extreme peaks in current and have the
capability of shutting down the screw press motor if the motor current exceeding a pre-set
value. In the vent the screw press control fails, it shall have the capability of switching to a
manual system.

The Screw Press Control Console shall be powered by Industrial PC with touch screen
functionality of which meets the requirements of Item 23: Systems Requirements

23. Systems Requirements


Considering the fact that palm oil milling rely on equipment / machinery to rapidly produce
crude palm oil (CPO) of the highest quality on a daily basis, it is appropriate in investing the
right technology with reliable equipment / machinery is critical. In such a case, it is crucial
for contractors to fulfill this system requirement as stated below;

23.1 Additional requirements for the Hydraulic Power Packs

The power packs shall be engineer to meet the demanding requirements of Crude palm Oil
Processing plant without the necessity of a heat exchanger to maintain optimum operating
temperature. The power packs shall incorporate oil level protection to prevent accidental
spillage of hydraulic oil and in the event of oil spillage, automatically sound an alarm to draw
attention

The power packs shall be robust in construction with a power capacity rated (with sufficient
safety factor) to meet the flow and pressure demands of the specific application.

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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Technical Specifications and Descriptions
23.2 Additional requirements for the Remote Control Console

The remote control console shall be of industrial grade with adequate forced ventilation to
ensure the uninterrupted operation of the control electronics housed within the respective
consoles. The console cabinets shall be dust and water proof and provide for easy access in
the event repair and/or servicing were required. Aside from housing the industrial grade
controller, the Remote Control Console shall house a relay system to accommodate
switching to manual in the event of redundancy. Cannon socket bayonet connections shall
be used for the connection of control cables.

23.3 Redundancy System

The systems are integrated with redundancy system override to provide manual mode
operations as a backup system in the event of electronic malfunction. This further
underwrites the reliability and up-time of the system.

23.4 Hydraulic Oil Sudden Leakage Sensor

All power packs are fitted with the Hydraulic Oil Sudden Leakage Sensor. The hydraulic
systems should be designed in cooperation with this sensor to provide immediate alarm in
the event of overflow or sudden leakage in the power packs and hydraulic piping.

23.5 High-Low Speed Control for Transfer Carriage

All transfer carriage should be fitted with automatic high-low speed control interface.

23.6 IP69K Grade Sensor (at Wet & Dry Area of the Sterilization Station)

All sterilizer work station sensors are with IP69K specification where environmental-rated to
meet the demands of the hardest working environment by withstanding the most severe
conditions in the mill.

23.7 IP67K Grade Sensor (at Wet & Dry Area of the Indexer Station)

All indexer work station sensors are with IP67K specification where environmental-rated to
meet the demands of the hardest working environment by withstanding the most severe
conditions in the mill.

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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Technical Specifications and Descriptions
23.8 Independent PLC (Programmable Logic Controller)

All remote control console (RCC) shall be fitted with independent PLC.

23.9 Industrial PC Window XP Embedded SP2

Industrial PC for Sterilizer Process Automation is built on a powerful Windows XP embedded


platform which provide user with highly interactive visualization.

23.10 IP65 Touch Screen

Control console must be fitted with IP65 Industrial PC with touch screen functionality.

23.11 Stainless Steel Drawbridge Rod (at Wet Area)

Stainless Steel precise machined Drawbridge Cylinder Rod being used to confirm the
cylinder is built to meet the demands of the severe conditions with longer life expectancy.

23.12 Thermoplastic High Pressure Flexible Hose

All hydraulic flexible hoses should be using Thermoplastic type due to corrosion, wet &
vaporized, and high pressure & temperature working condition.

23.13 Hydraulic Tubing

All hydraulic tubing is made of carbon steel, to withstand the maximum pressure of 5000psi
due to the demands of severe working conditions with longer life expectancy.

23.14 NITROXILE Cylinder Seal Kit and Hard Chrome G4051 S45C Cylinder Rod

All indexer cylinders should be using NITROXILE seal kit and Hard Chrome G4051 S45C
cylinder rod to meet the demands of severe conditions with longer life expectancy.

23.15 FLUOROCARBON Cylinder Seal Kit and Hard Chrome G4051 S45C Cylinder Rod

All sterilizer door cylinders should be using Fluorocarbon seal kit and Hard Chrome G4051
S45C cylinder rod due to corrosion, wet & vaporized, and high pressure & temperature
working condition.

This information is exclusive property of Dolphin Corporation and without prejudice. Without their consent, it shall not be reprinted or
given to third parties.
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