Spesification Design Loading Ramp [PDF]

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SPESIFICATION DESIGN LOADING RAMP 1. Design Concept The basic concept of the Loading Ramp is to store the FFB received from the scheme before brought to the mill processing. The basic factors had to be considered; 1. Mill throughput and standard design operation hours. 2. Size & No. of cages/sterilizer 3. No. of sterilizer 4. System layout for unloading and loading the FFB to and from the loading ramp.



2. Loading Ramp Sizing The design selection parameters are follows; 1. Mill throughput



: T Ton ffb/hr



2. Standard design operation hrs



: 20 hrs



3. Cage size



: 2.5 Ton (standard)



4. No. of cages per sterilizer



: C cages.



5. No. of sterilizer



: S Nos



6. Storage capacity / door



: 10 Ton



7. Total FFB receiving hour



: 8 hrs (8am-4pm)



The selection no. of doors (bays) are tabulated as per table 1 below; BI L 1 2 3 4 5 6 7 8 9 1 0



PARAMETERS No. of cage per sterilizer No. of sterilizer used Estimated FFB received per day, Ton FFB processed from 8 am to 4 pm (8 hours) Ton Balance to be stored inside the loading ramp, Ton Loading Ramp capacity per door, Ton No. of doors required. Existing No. of doors. Existing storage capacity, Ton Surplus capacity to be stored on the concrete platform, Ton



MILL THROUGHPUT 30 MT/H 40 MT/H 60 MT/H 9 8 11 3 4 4 600 800 1200 240 320 480 360 10 36 24 240



480 10 48 32 320



720 10 72 48 480



120



160



240



From Table 1 above, the actual total storage capacity is 50% higher than the existing storage capacity. The excess of 50% FFB normally will be dumped onto



the unloading concrete platform. It is estimated that 30% of the concrete area will be utilized. This phenomena is only happened during crop season. 3. Hydraulic System Selection



F : Force to move the door L : Load on the ramp door µ : Coefficient of friction : 0.15



Cylinder : W40 x 2⅟₂” bore x 36” stroke (Vickers)



Hydraulic force to pull the cylinder



: A₁ (P)



Hydraulic force to push the cylinder



: A (P)



A₁



: Annulus area : 2.5 in2



A



: Piston area : 4.91 in2



P



: hydraulic pressure



0.15(10000)(9.81) ⅟₂ sin 53⁰ = 1.6129 x 10³ P *P



: 3643103 N/m² : 36.43 bar : 528.25 psi : 550 psi



System pressure, P₁ = P + pressure drop along the tubing (⌂P) Estimation of pressure drop, ⌂P Length of tubing/door



: 15.5m



No. of door/side



: 24 Nos/Twin Pump



Total Length



: 186 m



Friction loss factor : 0.786 psi/metre run 



Total friction loss ≈ 150 psi



* Minimum system pressure required for hydraulic, P₁ is 700 psi (minimum) System (working pressure) selection



: 700 x 1.5 (S.F)



: 1050 psi



Speed of cylinder Volume swept when cylinder extend



: 4.91 x 36 in³



: 176.76 in³ (2.897 lit.) Volume swept when cylinder retract



: 2.5 x 36 in³



: 90 in³ (1.475 lit.) Pump flowrate



: 6 gpm (US) (22.73 lit/min)



Therefore, Extend time : 7.65 sec. Retract time : 3.9 sec. Cycle time



: 11.55 sec.



Extend speed



: 4.7 in/sec.



Retract speed



: 9.2 in/sec.



Ave speed



: 35 fpm



Hydraulic power (HP)



: (flowrate (gpm) x pressure (psi) x S.F) / 1714



: ( 6 x 700 x 1.5 ) / 1714 : 3.7 HP Motor horsepower : 3.27 kw ≈ 4 kw