APPENDIX Technical Specifications Conversion of the PU Foam Production Line Al-Essa for Refrigeration and Air-conditioning Co. Ltd. Riyadh, Saudi Arabia. Introduction Suppliers raw materials - Baalbaki, APC (Huntsman Arabian polyol co.), Bayer (Pearl insulation system house) Choice of technology to phase out HCFC The technology chosen is C-Pentane for the production of commercial Chest refrigerators and freezers. The choice of the type of pentane is not relevant for the production equipment. Products produced The company produces a range of chest refrigerators and freezers mainly for commercial purposes, models varying from 200 to 600 litres with foam weights up to 0 kg.
APPENDIX Existing machinery in use The company uses 2 Cannon HP machines from 985 one for door and one for cabinet foaming. The dry part consists of moveable fixtures driven by a chain system with about 5 fixtures in production. The fixtures have an aluminium core and before foaming pass through a pre-heating oven which is partially heated with heating elements. Typical cycle time is around one minute and foaming is performed at about kg/sec. The heating system needs to be reviewed as the electrical heating elements are not EX type and an external blower type heater is advisable.the heating system along with ceramic electrical heaters also have hot water radiators (curing oven temperature is maintained by these water heaters), electrical heaters are for providing direct heat to the cabinets and door moulds after chemical injection. Foaming is done with the cabinets in Bell position. After the curing the fixtures are opened by means of a manipulator. The fixtures itself do not have electrical equipment mounted on and therefore do not need to be modified. Cabinet fixture before foaming Foaming machine with mixing head mounted on boom 2
APPENDIX The doors are foamed on a separate production line on which the moulds are placed vertically and moved also moved through a preheating and curing oven. This oven is also equipped with heating elements and needs to be reviewed from safety point of view as the heaters are not EX. For foaming, the moulds are moved automatically in horizontal position and injection is accomplished through an injection hole with a closed mould. Foaming is done at about 500 grams/sec. Transport system for door moulds Door moulds manipulator for tilting the moulds in horizontal position For the doors and cabinets the existing booms for the mixing heads can be re-used but for using pentane a Nitrogen injection device will be required. 2. Equipment requested for conversion The foaming machines need to be replaced with machines suitable for the use of Pentane. Additionally a premixing unit is requested which would be used by both machines. 3
APPENDIX A safety system is required including ventilation, gas sensors and nitrogen injection before foaming into the cabinet and door fixtures. The beneficiary will take care of providing a room for placement of the premixing unit as well as storage of pentane drums. A room is already available for the storage of polyol and Isocyanate drums but it will need to be modified according to indications of the Contractor. 3. Technical specification Equipment specification for conversion of a commercial refrigeration cabinet and door line The offer must include: - 2 x High pressure foaming machine - x Safety system with gas sensors and ventilation - 2 x Nitrogen blanketing of fixtures and moulds - x Premix unit Polyol/Pentane - x ancillary equipment and services Therefore, the offer should include the following items: Nr. Description 2 Electrical cabinet - Pentane systems Safety cabinet and equipment 2 Worktank Isocyanate non flammable blowing agent 2 Worktank Polyol flammable blowing agent 2 Metering unit Isocyanate 2 Metering unit Polyol / Pentane Premix unit Polyol / Pentane 2 Mixing head suitable for PENTANE 2 Mixing head flexible hoses and mixing head support 2 Nitrogen injection Pentane storage tank equipment set Documentation set Safety whitebook Performance of metering units, machine output, premix unit, mixing head ) Performance for Cabinet foaming high pressure machine High pressure Metering unit Size of the pump (cc) Output of the pump (l/min) Contractor to enter data of size and output Polyol/ Pentane >= 28 cc >= 37 l/min..cc, l/min Isocyanate >= 28 cc >= 37 l/min..cc, l/min 2) Performance for Door foaming high pressure machine High pressure Size of the pump Output of the pump Contractor to enter 4
APPENDIX Metering unit (cc) (l/min) data of size and output Polyol/ Pentane >= 2 cc >= 6 l/min..cc, l/min Isocyanate >= 2 cc >= 6 l/min..cc, l/min Premixing unit Polyol with Pentane - Output > 20 l/min Mixing head ) Cabinet foaming mixing head - Size (internal diameter outlet pipe) >= 8 mm - Output with ratio : abt. kg/sec laminar flow 2) Door foaming mixing head - Size (internal diameter outlet pipe) >= 8 mm - Output with ratio : abt. 500 gram/sec laminar flow 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 specification Electrical cabinet - Pentane systems Cabinet Sufficiently sized for sealevel and ambient temperature 40 C with cooling Electrical parts set International Contractors Industrial computer International brand PLC with modules for EX parts Control panel >5 Inch touch-screen 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 Mixhead control panel machine room, otherwise a second panel has to be provided!) Electrical wires set According to EU standards Cable channels set Galvanised steel Signalisation Acoustical horn, status lamp (3 colours) 5 Contractor has to explain the foam program selection and placement of control panel or provide a price as option for a second panel.
APPENDIX EX parts Certification set Safety barriers for all electrical equipment polyol/pentane side ATEX, VDE, CE certification according to EU regulation For the complete plant: Safety cabinet and equipment Item Qty. Description Cabinet Sufficiently sized for sea level and ambient temperature 40 C with cooling Electrical parts set International Contractors Safety gas sensors foaming area 6 Gas sensors for cabinet and door foaming area Safety gas sensors foaming equipment 6 2 gas sensors for each foaming machine and 2 sensors for premix unit which also include storage area pentane drums Ventilation Double ventilator for foaming machine 2 and premix unit Ventilation Double ventilator for premix unit and Ventilation ducting Safety contacts Interface Remote alarm Grounding set 2 set storage area pentane drums Around foaming area, high pressure foaming machine and premix unit/pentane storage with sufficient flow throttle valves and evacuation points Potential free safety contact for power 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 non flammable blowing agent Worktank Volume minimal 250 l, min. 4 bar Cooling Double wall for water cooling with safety valve (when required) Level indicator Continuous level indicator with min and max alarm Supermax Separate supermax level sensor Pressurization Compressed air pressure regulator with safety valve and water sieve 6
APPENDIX Safety valve 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 External Plate heat exchanger welded type, with dt of >5 C Heat exchanger Temperature PT 00 Charging Piping Temperature control 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 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 unit feeding heat exchanger and double wall work tank with temperature controller, flex piping, valves, temperature sensor. Heating and cooling power to be indicated. Provide cooling power (KW) for the beneficiary chiller. Note: Chiller is not in the scope of supply! Worktank Polyol Flammable blowing agent Worktank Volume minimal 250 l, min. 0 bar Cooling double wall for water cooling with safety valve (when required) Level indicator EX - continuous level indicator with min and max alarm Supermax EX - separate supermax level sensor Pressurization compressed air pressure regulator with safety valve and water sieve Safety valve 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 Stirrer Stirrer with Magnetic coupling and Heat exchanger Temperature EX - PT 00 Charging electrical drive motor External Plate heat exchanger welded type, with dt of >5 C Membrane pump, capacity >30 l/min, with EX-pneumatic ball valve, support structure, pressure regulator, EXpneumatic control valve and flexible 7 Provide RPM stirrer
APPENDIX Piping Temperature control connection to drum or tankstorage 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 unit feeding heat exchanger and double wall worktank with temperature controller, flex piping, valves, temperature sensor. Heating and cooling power must be indicated Provide cooling power (KW) for the beneficiary chiller. Note: Chiller is not in the scope of supply! Metering unit Isocyanate Metering unit Swashplate Axial Piston metering pump withhandwheel 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 Flowmeter Flowmeter with accuracy +/- % output Indicate accuracy, metering pump type and brand Filter Suction filter wire edge type with cleaning handle/knob Low pressure Digital low pressure gauge 0-50 bar with gauge display High pressure gauge Digital High pressure gauge 0-400 bar with display Pump drainage Manual high pressure relief valve with piping High pressure valve High pressure ball valve Low pressure recirculation Hydraulic recirculation valve with EX solenoid or pneumatic actuated valve Production piping 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 / Pentane Swashplate Axial Piston metering pump Metering unit with handwheel Pump size See performance parameters introduction 8
APPENDIX E-motor Single speed electrical motor, 500 rpm E-motor pump coupling Magnetic coupling suitable sized to avoid overheating Flowmeter Flowmeter with accuracy +/- % output metering pump 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 Hydraulic recirculation valve with EX recirculation solenoid or pneumatic actuated valve Production Connection with non-return valve on piping return line to worktank Piping Carbon Steel Spillage Metal or plastic removable collection collection basin underneath complete metering unit Indicate accuracy, type and brand For both foaming machines one common: Premix unit Polyol / Pentane Metering unit Double gear pump, pneumatic or other type of system, pump polyol and pump pentane total output >20 liter/min Mixture ratio 2 to 5% of pentane on polyol E-motor Depending on system chosen, EX type of motors, drives or valves Magnetic coupling suitable sized to avoid E-motor pump overheating for pentane, Polyol double coupling mechanical seal Filter Suction filter wire edge type for polyol with cleaning handle/knob Low pressure EX-Digital low pressure gauge 0-50 bar gauge 2 for polyol and pentane High pressure EX-Digital High pressure gauge 0-50 bar gauge Flow measurement 2 for mixture flowmeterpolyol, EXflowmeter Pentane Manual high pressure relief valve with piping Pump drainage High pressure valve High pressure ball valve Production connection with non-return valve to HP piping machine distance abt. 0 m Piping Carbon Steel Spillage Metal or plastic removable collection 9
APPENDIX collection Pentane drum charging Polyol charging tankstorage Pentane safety Pentane safety gas sensors 2 basis underneath complete metering unit Steel platform with spillage control for charging pentane from drum, inclusive of membrane pump sized according to premix unit and flow no-flow sensor Pneumatic valve, non-return valve and potential free contact for signalling start charging of beneficiary tank storage Autonomous ventilation system and encapsulation of the premix unit as well as pentane drum charging pentane sensors with interface with safety control board Mixing head suitable for PENTANE Mixing head L-Type mixing head Output max. See performance parameters introduction Size head Internal diameter outlet pipe suitable for flow speed <3 m/sec, laminar flow Position Vertical pouring for CABINET foaming and horizontal for DOOR foaming Sensors position sensors control and cleaning 2 piston EX Movement Manual with mounted on handle Control box Mounted on head Actuation Hydraulic with valves mounted on head or boom EX Other Outlet pipe with DIN thread for attachment of hose Nitrogen blanketing fixtures and moulds Injection device The nitrogen has to be injected before the foaming and can be performed directly through the mixing head or with a separate device. Control valves Solenoid or other valves for activating the nitrogen injection Pressure regulation and electronic Pressure pressure gauge for verification that regulation sufficient nitrogen is available. Flexible hose of abt. 0 m and holding Flexible hose bracket for injection device (rigid piping Set from the bottle storage to the injection 0
APPENDIX controls are provided by the beneficiary). Alarms Acoustical and visual alarm in case of malfunction or lack of Nitrogen. Control Software control and interface with foaming program Mixing head Boom cabinet and door line Mixhead bracket for vertical foaming of Mixhead support cabinets and horizontal foaming of doors Flexible hoses guide set Set of drawings for flexible hoses support and guide. The beneficiary will provide and install the system. The beneficiary has already booms and supports available Rigid Steel piping / mixhead electrical cables Abt Piping to fill the HP machine worktank to Premix unit to 50 be supplied and installed by beneficiary HP machine m according to specification of Contractor Supports and fixation Provided by beneficiary according to Contractor design Insulation PU or other type of insulation >20 mm Flexible hoses Mixhead electrical cables 50m App 20m set thickness Flexible hoses for hydraulics, Polyol/Pentane and Isocyanate to the mixing head to be provided by the CONTRACTOR. Set of electrical cables according to required length Contractor must include in the scope of supply Contractor must include in the 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 Storage Tank Equipment
APPENDIX Double membrane pumps with pulsation Feed pumps damper or pump according to choice of Indicate clearly the Contractor with sufficient output for output and type of Set the production line 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 device for double wall of leakage control the tank Pressure Pressure relief valve on feed line to keeping valve Pressure keeping valve discount. block 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 4. Documentation Necessary documentation to be provided 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 Whitebook 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 whitebook 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 2
APPENDIX underground storage - Language manual and all component manuals: ENGLISH - All manuals in hard and electronic copy 5. Local Works (provided by the Beneficiary) The beneficiary will provide the following: - Room with air conditioning for storage of raw materials - Room for Pentane drums and premix unit according to drawings of Contractor - Electrical power supply to the E-cabinets of the Contractor 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 Contractor indication - Water heating of the presses - Power shut-off switch activated by potential free contact of Contractor safety system - Antistatic floor when required - Polyol/Pentane piping from the premix unit to the HP machine worktank - All required legal allowances - Sufficient raw materials for testing - Civil works (works related to the installation of the foaming machines) 6. Training Training on site at the Project Counterpart The Contractor shall provide 3 days training. All costs for flight, board and room shall be borne by the Contractor. Local transport will be provided by the beneficiary as well as lunch. The training shall be started after the commissioning has been finished and acceptance signed. 7. Implementation/Installation/Personnel Contractor scope Bidders shall specify in their proposals the implementation schedule as well as the number, details, and CVs of key personnel. The beneficiary will provide Electrical-, Mechanical engineer as well as sufficient workers. Specific lifting equipment and tools required for the installation should be timely notified by the Contractor to the beneficiary. All costs for flight, board and room shall be borne by the Contractor. Local transport will be provided by the beneficiary as well as lunch. 3
APPENDIX Responsibilities of the Beneficiary Based on the final detailed technical information provided by the Contractor, the beneficiary will prepare all required local works. One month before shipment of the equipment the Contractor has the right to visit the installation site and verify the status of work. In case of severe deviations by either party, the parties agree to inform each other so that eventual delays can be discussed on a timely basis. Safety verification The verification of the proper installation performed by the Contractor in full compliance with the Whitebook shall be performed jointly by the Contractor and the beneficiary and shall be properly documented. 8. After Sales Service During the first year of operation a minimum of two visits of service engineers should be envisaged by the Contractor for trouble shooting and general after sales service. One engineer visit after one calendar quarter and one visit at the end of the warranty period. If some problems concerning equipment and technology occur during the process of production and the beneficiary cannot resolve them, also through assistance with other means of communication, the Contractor shall send proper qualified personnel to the beneficiary site assisting to resolve the problems. The expenses in connection with such work shall be borne by the Contractor in case these problems are attributed to the equipment or technology during the warranty period. In case the problems are due to wrong handling of the equipment the beneficiary shall bear the costs of the not programmed after sales service visits. 9. Warranty period 2 months from the date of final acceptance but not longer than 24 months after shipment 0. Packaging and transport conditions Packaging for sea transport DAP Riyadh Kingdom of Saudi Arabia shall be performed by the Contractor, by duly considering the type and nature of the equipment.. Timeline The delivery of equipment has to be accomplished no later than six (6) months of contract signature. The installation and commission shall be accomplished not later than two (2) months after the delivery of equipment at work site. 4