Technical Specification Insulated Roofs and Walls Ind. Co. Ltd (HESCO) Jeddah. Content Introduction... Company data... 2 Consumption data PU Foam... 2 Suppliers raw materials... 3 Choice of technology to phase out HCFC... 3 Products produced... 3 Existing machinery in use... 3 Equipment requested for conversion... 6 Technical specification... 6 Local Works...2 Evaluation Criteriia...22 Introduction This project document contains general data of the company required for administrative purposes and a specification. The specification starting with a description of the existing machinery will be used for the tendering. Therefore carefully read the chapters starting from existing machinery in use.
Company data Description Your data Ownership 00% Export MLF fund GCC countries, AFRICA, MIDDEL EAST No Date of establishment: 980 Complete address head office Po Box 8 Jeddah 2453 Complete address factory Industrial area no., Phase no 3 Telefon number +966 2 637 8000 Fax number +966 2 6364 566 E-Mail Website Contact person Plant Manager Production manager General manager Owner of the company info@hesco-sa.com www.hesco-sa.com Eng. Tariq M. Basurrah (Vice-GM) Eng. Osama A. Hijazi (operations manager) Mr. S. Leela Krishnan Mr. Dhiya Hasrat Mr. Faisal Al Mahdi Consumption data PU Foam
Sandwich panels for wall and roof (metal to metal) Actual consumption Blowing agent 2007 2008 2009 200 20 202 HCFC-4b (MT) 55 70 7 87 05 25 Polyol (MT) 367 467 474 580 700 834 Isocyanate (MT) 54 654 663 842 980 67 Please all the data in MT (Metric Ton = 000 kg) as unit. Suppliers raw materials Please indicate your suppliers of raw materials - Huntsman, Basf, Bayer The raw materials are provided in drum Choice of technology to phase out HCFC The technology chosen is Pentane N or N/I for the continuous sandwich panel and block production. Products produced Continuous sandwich panels with metal facing. Existing machinery in use The company is equipped with a continuous sandwich panel production line manufactured by the company Hennecke in 98. The line is fully equipped from un-coilers and profiling of the metal or aluminum sheets to foaming, cutting and packaging. The company produced panels with metal facings and the conveyor length is 8 m. The foaming machinery has been well maintained but cannot be used for the conversion to Pentane and needs to be replaced completely. The machinery is in an enclosed air conditioned room and the company will provide a room for the new foaming machinery suitable sized.
The raw material are supplied in drums and charged inside tanks placed in a separate room. The room is temperature controlled and the tanks are equipped with pumps for transfer to the metering unit. The foaming portal will remain as it is and the movement is pneumatically controlled. What will be considered is the replacement of the position sensors. The control board will be kept for control of the production line but is of no use for the foaming machine conversion. Mixing head and drive mechanism
Conveyor side view with side chain A ventilation duct will be required under the side chain.pleas NOTE :THAT OUR CHAIN WITH SIDE BLOCKS ARE MOVING INSIDE & OUTSIDE THE DOUBLE BELT TO GIVE A DIFFERENT PANEL WIDTH. View of foaming portal mechanism (red housing), the foaming machine room will be placed next to this housing. The pentane tank will be placed outside behind the wall in the background on the picture. The heating of the conveyor is by means of air heated by electrical resistances. The supplier has to advise if this heating is save enough and which changes are required.
The tank storage consists of the following tanks: Tank storage Brand Polyol tanks Isocyanate 4b Thermal conditioning Pumps Additives Controls Local x 25M3, > Hennecke Supply (Hinkel+Diens Siegen Weldenau) x 0M3, x 5M3 > Local Supply x 25M3 x 2.5M3 ( to 2 bar) > Thyssen Umformtechnik With, air conditioned room gear pumps (polyol pump for three tanks) Drum charging worktanks Electromechanical All the piping to the worktanks is already available and for the new machine the beneficiary will provide the connections. The tranversal cutter is a rotating blade type but it producing sparks during the cutting process. Therefore the proposal has to contain the repair of the cutter and as option a new belt cutter. Note that the cutter is inside a room with evacuation of the cutting rests. Equipment requested for conversion - 4 component high pressure foaming machine inclusive of mixing head - Pentane tank ancillary equipment and drawings for the tank - Safety system with gas sensors and ventilation system - Cutter repair and option for a belt cutter - Revision of the heating system conveyor - Ancillary equipment Technical specification Equipment specification for conversion of continuous sandwich panel line The offer is for:
x High pressure foaming machine with Iso, Polyol, Pentane and activator x Pentane storage equipment x ancillary equipment and services Note: the pentane tank storage and feed pumps must be suitable for delivering pentane to the continuous sandwich panel line and the discontinuous rigid PU block production. and should include the following items: Nr. Description Electrical cabinet - Pentane systems Safety cabinet and equipment Worktank Isocyanate non Flammable blowing agent Worktank Polyol non Flammable blowing agent Worktank activator Metering unit Isocyanate Metering unit Polyol Metering unit activator Metering unit Pentane Mixing head continuous panel suitable for PENTANE Mixing head flexible hoses and mixing head support Pentane storage tank equipment set set Documentation Safety whitebook Performance of metering units, machine output, premix unit, mixing head
High pressure Metering unit Size of the pump (cc) Output of the pump (l/min) Supplier to enter data of size and output Polyol/ Pentane >= 2 cc 2 to 6 l/min..cc, l/min Isocyanate >= 2 cc 2 to 6 l/min..cc, l/min Activator 0.5 to 2 l/min..cc, l/min Pentane 0.5 to 3 l/min..cc, l/min Electrical power supply of the beneficiary factory: 380 V 60 Hz 3 phase + PE + earth < +/- 0% power fluctuation The various items should comply with the below detailed specifications: Electrical cabinet - Pentane systems Cabinet Sufficiently sized for sea level and ambient temperature 40 C with cooling Electrical parts set International suppliers Industrial computer International brand PLC with modules for EX parts Control panel >5 Inch touch-screen Mixhead control panel Mixing head electrical box for start, stop (Ex version) and foam program selection (the same panel of the main cabinet can be used when this is placed outside the Supplier to detail explain the foam program selection and placement of
machine room, otherwise a second panel to be provided!) control panel or provide a price as option for a second panel. Electrical wires set According to EU standards Cable channels set Galvanised steel Signalisation EX parts Certification set Acoustical horn, status lamp (3 colours) Safety barriers for all electrical equipment polyol/pentane side ATEX, VDE, CE certification according to EU regulation Safety cabinet and equipment Item Nr. Description Cabinet Sufficiently sized for sea level and ambient temperature 40 C with cooling Electrical parts set International suppliers Safety gas sensors prod. line 6 Safety gas sensors foaming equipment 4 Gas sensors for conveyor and finishing line 2 gas sensors for foaming machine and 2 sensors for pentane tank which includes also storage area pentane drums Ventilation Double ventilator for foaming machine Ventilation Ventilation Ventilation ducting set Double ventilator for conveyor and foaming area Double ventilator for pentane drum storage area Around conveyor, foaming machine and pouring areat with sufficient flow throttle valves and evacuation points Safety contacts 2 Potential free safety contact for power
Interface Remote alarm Grounding set shutoff beneficiary power supply Power shutoff interface with foaming equipment, premix and dry part beneficiary Remote alarm station with acoustical horn and status lamp alarm with 50 m cables Grounding connections for supplied equipment and cabling for grounding beneficiary dry part Worktank Isocyanate Worktank Volume minimal 250 l, min. 4 bar Cooling Level indicator Double wall for water cooling with safety valve (when required) Continuous level indicator with min and max alarm Supermax Separate supermax level sensor Pressurization Safety valve Compressed air pressure regulator with safety valve and water sieve Safety valve CS or greycast with pressure release rigid piping Insulation Armaflex or mineral wool with Al covering Exit valve Manual exit valve Drainage Manual drainage valve Stirrer Stirrer and electrical drive motor Heat exchanger External Plate heat exchanger welded type, with dt of >5 C Temperature PT 00 Charging Membrane pump, capacity >30 l/min, with pneumatic ball valve, support structure, pressure regulator, pneumatic control valve and flexible connection to drum or
tank storage Piping Rigid steel piping from metering unit to worktank, flexible piping allowed from worktank to metering unit, piping for charging rigid on worktank flexible to membrane pump Temperature control Temperature control unit feeding heat exchanger and double wall worktank with temperature controller, flex piping, valves, temperature sensor. Heating and cooling power to be indicated. Provide cooling power (KW) beneficiary chiller. Note: Chiller is not scope of supply! Worktank Polyol Worktank Volume minimal 250 l, min. 4 bar Cooling Level indicator double wall for water cooling with safety valve (when required) continuous level indicator with min and max alarm Supermax separate supermax level sensor Pressurization Safety valve compressed air pressure regulator with safety valve and water sieve safety valve CS or greycast with pressure release rigid piping Insulation Armaflex or mineral wool with Al covering Exit valve Pneumatic exit valve Drainage Manual drainage valve with Lock Stirrer Stirrer with Magnetic coupling and electrical drive motor Provide rpm stirrer Heat exchanger External Plate heat exchanger welded type, with dt of >5 C Temperature PT 00 Charging Membrane pump, capacity >30 l/min, with pneumatic ball valve, support structure,
pressure regulator, pneumatic control valve and flexible connection to drum or tank storage Piping Rigid steel piping from metering unit to work tank, flexible piping allowed from work tank to metering unit, piping for charging rigid on work tank flexible to membrane pump Temperature control Temperature control unit feeding heat exchanger and double wall worktank with temperature controller, flex piping, valves, temperature sensor. Heating and cooling power to be indicated Provide cooling power (KW) beneficiary chiller. Note: Chiller is not scope of supply! Worktank Activator Flammable Worktank Volume minimal 250 l, min. 0 bar Cooling Level indicator double wall for water cooling with safety valve (when required) EX - continuous level indicator with min and max alarm Supermax EX - separate supermax level sensor Pressurization Safety valve compressed air pressure regulator with safety valve and water sieve safety valve CS or greycast with pressure release rigid piping Insulation Armaflex or mineral wool with Al covering Exit valve EX - Pneumatic exit valve Drainage Manual drainage valve with Lock Heat exchanger External Plate heat exchanger welded type, with dt of >5 C
Temperature EX - PT 00 Charging Membrane pump, capacity >30 l/min, with EX-pneumatic ball valve, support structure, pressure regulator, EXpneumatic control valve and flexible connection to drum or tank storage Piping Rigid steel piping from metering unit to work tank, flexible piping allowed from work tank to metering unit, piping for charging rigid on work tank flexible to membrane pump Temperature control Temperature control unit feeding heat exchanger and double wall worktank with temperature controller, flex piping, valves, temperature sensor. Heating and cooling power to be indicated Provide cooling power (KW) beneficiary chiller. Note: Chiller is not scope of supply! Metering unit Isocyanate Metering unit Swashplate Axial Piston metering pump with hand wheel Pump size See performance parameters introduction E-motor Single speed electrical motor, 500 rpm E-motor pump coupling Magnetic coupling suitable sized to avoid overheating Filter Suction filter wire edge type with cleaning handle/knob Low pressure gauge Digital low pressure gauge 0-50 bar with display High pressure Digital High pressure gauge 0-400 bar
gauge Pump drainage with display Manual high pressure relief valve with piping High pressure valve High pressure ball valve Low pressure recirculation Production piping Hydraulic recirculation valve with EX solenoid or pneumatic actuated valve Connection with non-return valve on return line to worktank Piping Carbon Steel Spillage collection Metal or plastic removable collection basin underneath complete metering unit Metering unit Polyol Metering unit Swashplate Axial Piston metering pump with hand wheel Pump size See performance parameters introduction E-motor Single speed electrical motor, 500 rpm E-motor pump coupling Magnetic coupling suitable sized to avoid overheating Filter Suction filter wire edge type with cleaning handle/knob Low pressure gauge Digital low pressure gauge 0-50 bar High pressure gauge Digital High pressure gauge 0-400 bar Pump drainage Manual high pressure relief valve with piping High pressure valve High pressure ball valve
Low pressure recirculation Production piping Hydraulic recirculation valve with EX solenoid or pneumatic actuated valve Connection with non-return valve on return line to worktank Piping Carbon Steel Spillage collection Metal or plastic removable collection basin underneath complete metering unit Metering unit Activator Metering unit Double high pressure membrane Pump Indicate pump brand and type E-motor Flowmeter Filter Single speed electrical motor, 500 rpm with Frequency control Flowmeter with accuracy +/- % output metering pump Suction filter wire edge type with cleaning handle/knob Indicate accuracy, type and brand Low pressure gauge High pressure gauge Temperature sensor Digital low pressure gauge 0-50 bar Digital High pressure gauge 0-50 bar PT00 Pump drainage manual high pressure relief valve with piping High pressure valve High pressure ball valve Low pressure Hydraulic recirculation valve with EX
recirculation Spillage collection solenoid valve Metal or plastic removable collection basis underneath complete metering unit Metering unit Pentane Metering unit Double high pressure membrane Pump Indicate pump brand and type E-motor Single speed electrical motor, 500 rpm with Frequency control E-motor pump coupling Magnetic coupling suitable sized to avoid overheating Flowmeter Filter Flowmeter with accuracy +/- % output metering pump Suction filter wire edge type with cleaning handle/knob Indicate accuracy, type and brand Low pressure gauge High pressure gauge Temperature sensor EX-Digital low pressure gauge 0-50 bar EX-Digital High pressure gauge 0-50 bar EX-PT00 Pump drainage manual high pressure relief valve with piping High pressure valve High pressure ball valve Low pressure recirculation Spillage collection Hydraulic recirculation valve with EX solenoid valve Metal or plastic removable collection basis underneath complete metering unit
Mixing head suitable for PENTANE Mixing head Straight type with pouring rake Output max. See performance parameters introduction Size head Suitable for range of output with 3 sets of rakes and 3 sets of nozzles Position Vertical pouring Cleaning piston for air or hot water cleaning Movement Mounting bracket for existing manipulator Control box N/A Actuation Hydraulic/ pneumatic Mixing head Boom The beneficiary is using the press and has a support for the flexible hoses etc. in order to provide a suitable installation the following is requested Mixhead support Mixhead bracket for horizontal foaming Flexible hoses guide Electrical parts set set Set of drawings for flexible hoses support and guide. The beneficiary will provide and install the system. Replacement of sensors and position indicators according to the safety concept put in place
Static or dynamic mixer of Polyol, Activator and pentane Mixer High pressure Variable speed dynamic mixer or static mixing system Provide detailed system description N 2 nucleation High pressure N 2 polyol nucleation with static mixer and N 2 flowmeter Inlet ports 5 inlet ports for Polyol, pentane, activator and future additional activator/polyol with non-return valves E-motor EX type motor variable speed drive E-motor pump coupling Magnetic coupling Piping Static mixer Rigid piping to HP machine and connection to mixhead with flexible hoses Depending on the technology chosen the pentane is allowed to be mixed in-line with a static mixer Rigid Steel piping / mixhead electrical cables HP machine to dry part Premix unit to HP machine Supports and fixation Abt. 0m Abt 50 m Set of rigid piping for supply of polyol/pentane, Isocyanate and hydraulics to be purchased by the beneficiary from HP machine to dry part Piping to fill the HP machine worktank to be supplied and installed by beneficiary according to specification of supplier Provided by beneficiary according to supplier design
Insulation 50m PU or other type of insulation >20 mm thickness Flexible hoses App 20m Flexible hoses for hydraulics, Polyol/Pentane and Isocyanate to the mixing head to be provided by the SUPPLIER. Supplier to confirm inclusion in scope of supply Mixhead electrical cables set Set of electrical cables according to required length Supplier to confirm inclusion in scope of supply Note the HP machine must be suitable dimensioned for the above indicated piping lengths Note the beneficiary will provide a suitable room for placement of the machine All the piping lengths are approximate Pentane tank storage equipment Feed pumps Set Double membrane pumps with pulsation damper or pump according to choice of the supplier with sufficient output for the production line Indicate clearly output and type of pump proposed Pressure sensor Pressure manometer or guage Temperature sensor PT 00 in feed line Tank charging Set of ball valves pneumatically operated and grounding plier for loading by gravity Double wall leakage control Pressure keeping valve Pressure keeping valve discount. block Leakage control device for double wall of the tank Pressure relief valve on feed line to metering pump continuous line Pressure relief valve on feed line to metering pump discontinuous block foaming equipment Safety valve Safety valve Level control Continuous level control
Tank blanketing Electrical control Safety valve, pressure regulator and ancillary equipment for tank blanketing with Nitrogen Electrical cabinet for control of the pumps, interface with production equipment, grounding and tank loading inclusive of acoustical horn and warning lamps Standards All equipment for ATEX Zone 0 Drawings Set Drawing for double wall pentane tank 5 to 20 T for the underground storage Cutting saw - repair E-motor 2 Replacement of electrical motors and circular blade drive ATEX certified Indicate clearly output and type of pump proposed Cutting blades 2 Substitution of cutting blades Note the shreds evacuation as well as a room are already available. Option: New cutting saw Belt cutter Complete belt cutter for transversal cut Belt cutter according to ATEX with movement system according to speed of the line 2 to 5 m/min. Inclusive of controls. Indicate clearly output and type of pump proposed E-motor Replacement of overlap cut electrical motor and circular blade drive ATEX certified Indicate clearly output and type of pump proposed Cutting blades Substitution of cutting blades
Documentation Nr. Description + User manual + Maintenance and repair manual + Spare parts manual + List of certifications, ATEX, CE, Pressure vessel, safety valves etc. of all components + Electrical cabinet VDE, CE certification according to EU + Electrical cabinet electrical diagram White book with layout of the factory (dwg drawing will be provided by the + beneficiary) and description of all the safety measures taken for the use of Pentane. This white book shall be according to TüV standards and can upon the decision of the beneficiary be submitted to the TüV. + Full installation report with settings of the machinery, verification of all safety systems, commissioning record and final drawings, electrical schematic. + Layout drawings for premix room and pentane storage area + Layout drawings for High pressure foaming machine + Drawings for mixing head guide and support system + Drawings for the local manufacture of a 5 to 20 T pentane tank for the underground storage Language manual and all component manuals: ENGLISH All manuals in hard and electronic copy Local Works Each beneficiary will provide the following: - Room with air conditioner for storage of raw materials. AVAILABLE IN OUR ROOM - Room for Pentane Tank and premix unit according to drawings of supplier - Electrical power supply to the E-cabinets of the supplier equipment - Compressed air 6 bar minimum and piping to the HP machine - Nitrogen for blanketing of Polyol/pentane worktank and piping to the HP machine (bottles) - Chilled water for cooling HP machine - Ventilation ducting to the roof of the factory from the ventilators upwards - Grounding of the press and provision of grounding points according to supplier indication - Water heating of the presses. Our existing press is operated by E-heater which it is Outside of the press, only hot air re-cycled inside the press through the duct. A according to some manufacturer for new production lines, they are using An Electrical resistance inside their press and this type of heating system according to them is safe by using Pentane Gas. So please check this point. - Power shut-off switch activated by potential free contact of supplier safety system - Antistatic floor when required - Polyol/Pentane piping from the premix unit to the HP machine work tank - Pentane piping from tankstorage - All required legal allowances - Sufficient raw materials for testing - Room around the cutter of the continuous sandwich panel line
- Pentane tank 5 to 20 m3. 35 M3 of Pentane tank for our new production line will be connected too with our existing line. - Civil works Evaluation Criteria The following criteria will be used for technical evaluation of submitted proposals: Compliance with the requested technical specifications Delivery time for equipment and accessories for a maximum of 4 months from award of a Contract Availability of a local/regional agent for servicing of supplied equipment during the warranty period Attached Reference list of similar projects (for applied cyclopentane / n-pentane foaming technology) implemented during last 5 years Experience with Multilateral Fund for Montreal Protocol projects for conversion of PU foam production lines in developing countries Guarantee requirements for supplied and installed equipment
Technical Specification Insulated Roofs and Walls Ind. Co. Ltd (HESCO) Jeddah. Content Introduction... Company data... 2 Consumption data PU Foam... 2 Suppliers raw materials... 3 Choice of technology to phase out HCFC... 3 Products produced... 3 Existing machinery in use... 3 Equipment requested for conversion... 6 Technical specification... 6 Local Works...2 Evaluation Criteriia...22 Introduction This project document contains general data of the company required for administrative purposes and a specification. The specification starting with a description of the existing machinery will be used for the tendering. Therefore carefully read the chapters starting from existing machinery in use.
Company data Description Your data Ownership 00% Export MLF fund GCC countries, AFRICA, MIDDEL EAST No Date of establishment: 980 Complete address head office Po Box 8 Jeddah 2453 Complete address factory Industrial area no., Phase no 3 Telefon number +966 2 637 8000 Fax number +966 2 6364 566 E-Mail Website Contact person Plant Manager Production manager General manager Owner of the company info@hesco-sa.com www.hesco-sa.com Eng. Tariq M. Basurrah (Vice-GM) Eng. Osama A. Hijazi (operations manager) Mr. S. Leela Krishnan Mr. Dhiya Hasrat Mr. Faisal Al Mahdi Consumption data PU Foam
Sandwich panels for wall and roof (metal to metal) Actual consumption Blowing agent 2007 2008 2009 200 20 202 HCFC-4b (MT) 55 70 7 87 05 25 Polyol (MT) 367 467 474 580 700 834 Isocyanate (MT) 54 654 663 842 980 67 Please all the data in MT (Metric Ton = 000 kg) as unit. Suppliers raw materials Please indicate your suppliers of raw materials - Huntsman, Basf, Bayer The raw materials are provided in drum Choice of technology to phase out HCFC The technology chosen is Pentane N or N/I for the continuous sandwich panel and block production. Products produced Continuous sandwich panels with metal facing. Existing machinery in use The company is equipped with a continuous sandwich panel production line manufactured by the company Hennecke in 98. The line is fully equipped from un-coilers and profiling of the metal or aluminum sheets to foaming, cutting and packaging. The company produced panels with metal facings and the conveyor length is 8 m. The foaming machinery has been well maintained but cannot be used for the conversion to Pentane and needs to be replaced completely. The machinery is in an enclosed air conditioned room and the company will provide a room for the new foaming machinery suitable sized.
The raw material are supplied in drums and charged inside tanks placed in a separate room. The room is temperature controlled and the tanks are equipped with pumps for transfer to the metering unit. The foaming portal will remain as it is and the movement is pneumatically controlled. What will be considered is the replacement of the position sensors. The control board will be kept for control of the production line but is of no use for the foaming machine conversion. Mixing head and drive mechanism
Conveyor side view with side chain A ventilation duct will be required under the side chain.pleas NOTE :THAT OUR CHAIN WITH SIDE BLOCKS ARE MOVING INSIDE & OUTSIDE THE DOUBLE BELT TO GIVE A DIFFERENT PANEL WIDTH. View of foaming portal mechanism (red housing), the foaming machine room will be placed next to this housing. The pentane tank will be placed outside behind the wall in the background on the picture. The heating of the conveyor is by means of air heated by electrical resistances. The supplier has to advise if this heating is save enough and which changes are required.
The tank storage consists of the following tanks: Tank storage Brand Polyol tanks Isocyanate 4b Thermal conditioning Pumps Additives Controls Local x 25M3, > Hennecke Supply (Hinkel+Diens Siegen Weldenau) x 0M3, x 5M3 > Local Supply x 25M3 x 2.5M3 ( to 2 bar) > Thyssen Umformtechnik With, air conditioned room gear pumps (polyol pump for three tanks) Drum charging worktanks Electromechanical All the piping to the worktanks is already available and for the new machine the beneficiary will provide the connections. The tranversal cutter is a rotating blade type but it producing sparks during the cutting process. Therefore the proposal has to contain the repair of the cutter and as option a new belt cutter. Note that the cutter is inside a room with evacuation of the cutting rests. Equipment requested for conversion - 4 component high pressure foaming machine inclusive of mixing head - Pentane tank ancillary equipment and drawings for the tank - Safety system with gas sensors and ventilation system - Cutter repair and option for a belt cutter - Revision of the heating system conveyor - Ancillary equipment Technical specification Equipment specification for conversion of continuous sandwich panel line The offer is for:
x High pressure foaming machine with Iso, Polyol, Pentane and activator x Pentane storage equipment x ancillary equipment and services Note: the pentane tank storage and feed pumps must be suitable for delivering pentane to the continuous sandwich panel line and the discontinuous rigid PU block production. and should include the following items: Nr. Description Electrical cabinet - Pentane systems Safety cabinet and equipment Worktank Isocyanate non Flammable blowing agent Worktank Polyol non Flammable blowing agent Worktank activator Metering unit Isocyanate Metering unit Polyol Metering unit activator Metering unit Pentane Mixing head continuous panel suitable for PENTANE Mixing head flexible hoses and mixing head support Pentane storage tank equipment set set Documentation Safety whitebook Performance of metering units, machine output, premix unit, mixing head
High pressure Metering unit Size of the pump (cc) Output of the pump (l/min) Supplier to enter data of size and output Polyol/ Pentane >= 2 cc 2 to 6 l/min..cc, l/min Isocyanate >= 2 cc 2 to 6 l/min..cc, l/min Activator 0.5 to 2 l/min..cc, l/min Pentane 0.5 to 3 l/min..cc, l/min Electrical power supply of the beneficiary factory: 380 V 60 Hz 3 phase + PE + earth < +/- 0% power fluctuation The various items should comply with the below detailed specifications: Electrical cabinet - Pentane systems Cabinet Sufficiently sized for sea level and ambient temperature 40 C with cooling Electrical parts set International suppliers Industrial computer International brand PLC with modules for EX parts Control panel >5 Inch touch-screen Mixhead control panel Mixing head electrical box for start, stop (Ex version) and foam program selection (the same panel of the main cabinet can be used when this is placed outside the Supplier to detail explain the foam program selection and placement of
machine room, otherwise a second panel to be provided!) control panel or provide a price as option for a second panel. Electrical wires set According to EU standards Cable channels set Galvanised steel Signalisation EX parts Certification set Acoustical horn, status lamp (3 colours) Safety barriers for all electrical equipment polyol/pentane side ATEX, VDE, CE certification according to EU regulation Safety cabinet and equipment Item Nr. Description Cabinet Sufficiently sized for sea level and ambient temperature 40 C with cooling Electrical parts set International suppliers Safety gas sensors prod. line 6 Safety gas sensors foaming equipment 4 Gas sensors for conveyor and finishing line 2 gas sensors for foaming machine and 2 sensors for pentane tank which includes also storage area pentane drums Ventilation Double ventilator for foaming machine Ventilation Ventilation Ventilation ducting set Double ventilator for conveyor and foaming area Double ventilator for pentane drum storage area Around conveyor, foaming machine and pouring areat with sufficient flow throttle valves and evacuation points Safety contacts 2 Potential free safety contact for power
Interface Remote alarm Grounding set shutoff beneficiary power supply Power shutoff interface with foaming equipment, premix and dry part beneficiary Remote alarm station with acoustical horn and status lamp alarm with 50 m cables Grounding connections for supplied equipment and cabling for grounding beneficiary dry part Worktank Isocyanate Worktank Volume minimal 250 l, min. 4 bar Cooling Level indicator Double wall for water cooling with safety valve (when required) Continuous level indicator with min and max alarm Supermax Separate supermax level sensor Pressurization Safety valve Compressed air pressure regulator with safety valve and water sieve Safety valve CS or greycast with pressure release rigid piping Insulation Armaflex or mineral wool with Al covering Exit valve Manual exit valve Drainage Manual drainage valve Stirrer Stirrer and electrical drive motor Heat exchanger External Plate heat exchanger welded type, with dt of >5 C Temperature PT 00 Charging Membrane pump, capacity >30 l/min, with pneumatic ball valve, support structure, pressure regulator, pneumatic control valve and flexible connection to drum or
tank storage Piping Rigid steel piping from metering unit to worktank, flexible piping allowed from worktank to metering unit, piping for charging rigid on worktank flexible to membrane pump Temperature control Temperature control unit feeding heat exchanger and double wall worktank with temperature controller, flex piping, valves, temperature sensor. Heating and cooling power to be indicated. Provide cooling power (KW) beneficiary chiller. Note: Chiller is not scope of supply! Worktank Polyol Worktank Volume minimal 250 l, min. 4 bar Cooling Level indicator double wall for water cooling with safety valve (when required) continuous level indicator with min and max alarm Supermax separate supermax level sensor Pressurization Safety valve compressed air pressure regulator with safety valve and water sieve safety valve CS or greycast with pressure release rigid piping Insulation Armaflex or mineral wool with Al covering Exit valve Pneumatic exit valve Drainage Manual drainage valve with Lock Stirrer Stirrer with Magnetic coupling and electrical drive motor Provide rpm stirrer Heat exchanger External Plate heat exchanger welded type, with dt of >5 C Temperature PT 00 Charging Membrane pump, capacity >30 l/min, with pneumatic ball valve, support structure,
pressure regulator, pneumatic control valve and flexible connection to drum or tank storage Piping Rigid steel piping from metering unit to work tank, flexible piping allowed from work tank to metering unit, piping for charging rigid on work tank flexible to membrane pump Temperature control Temperature control unit feeding heat exchanger and double wall worktank with temperature controller, flex piping, valves, temperature sensor. Heating and cooling power to be indicated Provide cooling power (KW) beneficiary chiller. Note: Chiller is not scope of supply! Worktank Activator Flammable Worktank Volume minimal 250 l, min. 0 bar Cooling Level indicator double wall for water cooling with safety valve (when required) EX - continuous level indicator with min and max alarm Supermax EX - separate supermax level sensor Pressurization Safety valve compressed air pressure regulator with safety valve and water sieve safety valve CS or greycast with pressure release rigid piping Insulation Armaflex or mineral wool with Al covering Exit valve EX - Pneumatic exit valve Drainage Manual drainage valve with Lock Heat exchanger External Plate heat exchanger welded type, with dt of >5 C
Temperature EX - PT 00 Charging Membrane pump, capacity >30 l/min, with EX-pneumatic ball valve, support structure, pressure regulator, EXpneumatic control valve and flexible connection to drum or tank storage Piping Rigid steel piping from metering unit to work tank, flexible piping allowed from work tank to metering unit, piping for charging rigid on work tank flexible to membrane pump Temperature control Temperature control unit feeding heat exchanger and double wall worktank with temperature controller, flex piping, valves, temperature sensor. Heating and cooling power to be indicated Provide cooling power (KW) beneficiary chiller. Note: Chiller is not scope of supply! Metering unit Isocyanate Metering unit Swashplate Axial Piston metering pump with hand wheel Pump size See performance parameters introduction E-motor Single speed electrical motor, 500 rpm E-motor pump coupling Magnetic coupling suitable sized to avoid overheating Filter Suction filter wire edge type with cleaning handle/knob Low pressure gauge Digital low pressure gauge 0-50 bar with display High pressure Digital High pressure gauge 0-400 bar
gauge Pump drainage with display Manual high pressure relief valve with piping High pressure valve High pressure ball valve Low pressure recirculation Production piping Hydraulic recirculation valve with EX solenoid or pneumatic actuated valve Connection with non-return valve on return line to worktank Piping Carbon Steel Spillage collection Metal or plastic removable collection basin underneath complete metering unit Metering unit Polyol Metering unit Swashplate Axial Piston metering pump with hand wheel Pump size See performance parameters introduction E-motor Single speed electrical motor, 500 rpm E-motor pump coupling Magnetic coupling suitable sized to avoid overheating Filter Suction filter wire edge type with cleaning handle/knob Low pressure gauge Digital low pressure gauge 0-50 bar High pressure gauge Digital High pressure gauge 0-400 bar Pump drainage Manual high pressure relief valve with piping High pressure valve High pressure ball valve
Low pressure recirculation Production piping Hydraulic recirculation valve with EX solenoid or pneumatic actuated valve Connection with non-return valve on return line to worktank Piping Carbon Steel Spillage collection Metal or plastic removable collection basin underneath complete metering unit Metering unit Activator Metering unit Double high pressure membrane Pump Indicate pump brand and type E-motor Flowmeter Filter Single speed electrical motor, 500 rpm with Frequency control Flowmeter with accuracy +/- % output metering pump Suction filter wire edge type with cleaning handle/knob Indicate accuracy, type and brand Low pressure gauge High pressure gauge Temperature sensor Digital low pressure gauge 0-50 bar Digital High pressure gauge 0-50 bar PT00 Pump drainage manual high pressure relief valve with piping High pressure valve High pressure ball valve Low pressure Hydraulic recirculation valve with EX
recirculation Spillage collection solenoid valve Metal or plastic removable collection basis underneath complete metering unit Metering unit Pentane Metering unit Double high pressure membrane Pump Indicate pump brand and type E-motor Single speed electrical motor, 500 rpm with Frequency control E-motor pump coupling Magnetic coupling suitable sized to avoid overheating Flowmeter Filter Flowmeter with accuracy +/- % output metering pump Suction filter wire edge type with cleaning handle/knob Indicate accuracy, type and brand Low pressure gauge High pressure gauge Temperature sensor EX-Digital low pressure gauge 0-50 bar EX-Digital High pressure gauge 0-50 bar EX-PT00 Pump drainage manual high pressure relief valve with piping High pressure valve High pressure ball valve Low pressure recirculation Spillage collection Hydraulic recirculation valve with EX solenoid valve Metal or plastic removable collection basis underneath complete metering unit
Mixing head suitable for PENTANE Mixing head Straight type with pouring rake Output max. See performance parameters introduction Size head Suitable for range of output with 3 sets of rakes and 3 sets of nozzles Position Vertical pouring Cleaning piston for air or hot water cleaning Movement Mounting bracket for existing manipulator Control box N/A Actuation Hydraulic/ pneumatic Mixing head Boom The beneficiary is using the press and has a support for the flexible hoses etc. in order to provide a suitable installation the following is requested Mixhead support Mixhead bracket for horizontal foaming Flexible hoses guide Electrical parts set set Set of drawings for flexible hoses support and guide. The beneficiary will provide and install the system. Replacement of sensors and position indicators according to the safety concept put in place
Static or dynamic mixer of Polyol, Activator and pentane Mixer High pressure Variable speed dynamic mixer or static mixing system Provide detailed system description N 2 nucleation High pressure N 2 polyol nucleation with static mixer and N 2 flowmeter Inlet ports 5 inlet ports for Polyol, pentane, activator and future additional activator/polyol with non-return valves E-motor EX type motor variable speed drive E-motor pump coupling Magnetic coupling Piping Static mixer Rigid piping to HP machine and connection to mixhead with flexible hoses Depending on the technology chosen the pentane is allowed to be mixed in-line with a static mixer Rigid Steel piping / mixhead electrical cables HP machine to dry part Premix unit to HP machine Supports and fixation Abt. 0m Abt 50 m Set of rigid piping for supply of polyol/pentane, Isocyanate and hydraulics to be purchased by the beneficiary from HP machine to dry part Piping to fill the HP machine worktank to be supplied and installed by beneficiary according to specification of supplier Provided by beneficiary according to supplier design
Insulation 50m PU or other type of insulation >20 mm thickness Flexible hoses App 20m Flexible hoses for hydraulics, Polyol/Pentane and Isocyanate to the mixing head to be provided by the SUPPLIER. Supplier to confirm inclusion in scope of supply Mixhead electrical cables set Set of electrical cables according to required length Supplier to confirm inclusion in scope of supply Note the HP machine must be suitable dimensioned for the above indicated piping lengths Note the beneficiary will provide a suitable room for placement of the machine All the piping lengths are approximate Pentane tank storage equipment Feed pumps Set Double membrane pumps with pulsation damper or pump according to choice of the supplier with sufficient output for the production line Indicate clearly output and type of pump proposed Pressure sensor Pressure manometer or guage Temperature sensor PT 00 in feed line Tank charging Set of ball valves pneumatically operated and grounding plier for loading by gravity Double wall leakage control Pressure keeping valve Pressure keeping valve discount. block Leakage control device for double wall of the tank Pressure relief valve on feed line to metering pump continuous line Pressure relief valve on feed line to metering pump discontinuous block foaming equipment Safety valve Safety valve Level control Continuous level control
Tank blanketing Electrical control Safety valve, pressure regulator and ancillary equipment for tank blanketing with Nitrogen Electrical cabinet for control of the pumps, interface with production equipment, grounding and tank loading inclusive of acoustical horn and warning lamps Standards All equipment for ATEX Zone 0 Drawings Set Drawing for double wall pentane tank 5 to 20 T for the underground storage Cutting saw - repair E-motor 2 Replacement of electrical motors and circular blade drive ATEX certified Indicate clearly output and type of pump proposed Cutting blades 2 Substitution of cutting blades Note the shreds evacuation as well as a room are already available. Option: New cutting saw Belt cutter Complete belt cutter for transversal cut Belt cutter according to ATEX with movement system according to speed of the line 2 to 5 m/min. Inclusive of controls. Indicate clearly output and type of pump proposed E-motor Replacement of overlap cut electrical motor and circular blade drive ATEX certified Indicate clearly output and type of pump proposed Cutting blades Substitution of cutting blades
Documentation Nr. Description + User manual + Maintenance and repair manual + Spare parts manual + List of certifications, ATEX, CE, Pressure vessel, safety valves etc. of all components + Electrical cabinet VDE, CE certification according to EU + Electrical cabinet electrical diagram White book with layout of the factory (dwg drawing will be provided by the + beneficiary) and description of all the safety measures taken for the use of Pentane. This white book shall be according to TüV standards and can upon the decision of the beneficiary be submitted to the TüV. + Full installation report with settings of the machinery, verification of all safety systems, commissioning record and final drawings, electrical schematic. + Layout drawings for premix room and pentane storage area + Layout drawings for High pressure foaming machine + Drawings for mixing head guide and support system + Drawings for the local manufacture of a 5 to 20 T pentane tank for the underground storage Language manual and all component manuals: ENGLISH All manuals in hard and electronic copy Local Works Each beneficiary will provide the following: - Room with air conditioner for storage of raw materials. AVAILABLE IN OUR ROOM - Room for Pentane Tank and premix unit according to drawings of supplier - Electrical power supply to the E-cabinets of the supplier equipment - Compressed air 6 bar minimum and piping to the HP machine - Nitrogen for blanketing of Polyol/pentane worktank and piping to the HP machine (bottles) - Chilled water for cooling HP machine - Ventilation ducting to the roof of the factory from the ventilators upwards - Grounding of the press and provision of grounding points according to supplier indication - Water heating of the presses. Our existing press is operated by E-heater which it is Outside of the press, only hot air re-cycled inside the press through the duct. A according to some manufacturer for new production lines, they are using An Electrical resistance inside their press and this type of heating system according to them is safe by using Pentane Gas. So please check this point. - Power shut-off switch activated by potential free contact of supplier safety system - Antistatic floor when required - Polyol/Pentane piping from the premix unit to the HP machine work tank - Pentane piping from tankstorage - All required legal allowances - Sufficient raw materials for testing - Room around the cutter of the continuous sandwich panel line
- Pentane tank 5 to 20 m3. 35 M3 of Pentane tank for our new production line will be connected too with our existing line. - Civil works Evaluation Criteria The following criteria will be used for technical evaluation of submitted proposals: Compliance with the requested technical specifications Delivery time for equipment and accessories for a maximum of 4 months from award of a Contract Availability of a local/regional agent for servicing of supplied equipment during the warranty period Attached Reference list of similar projects (for applied cyclopentane / n-pentane foaming technology) implemented during last 5 years Experience with Multilateral Fund for Montreal Protocol projects for conversion of PU foam production lines in developing countries Guarantee requirements for supplied and installed equipment