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UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
TECHNICAL SPECIFICATION
for the Purchase of Equipment and Technical Services Required for the
Conversion of Rigid Polyurethane Foam blowing from
HCFC-141b to cyclopentane
MP/SUD/10/002
Umbrella project for the phase-out of HCFC-141b from the PU rigid foam production in the
manufacturing of Domestic Refrigerators, Commercial Refrigerators and PU insulated composite
panels.
Company
Akadabi Steel Co.
This Technical specification shall be used for the preparation of bids for the supply of equipment and technical
services required for the conversion of the production process in order to phase out the use of HCFC-141b in the
production of domestic refrigerators at the above mentioned factory. This document specifies the scope of
supply of goods and related services as well as the obligations and responsibilities of the supplier.
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1. BACKGROUND INFORMATION
1.1 PROJECT OBJECTIVE
The objective of this project is to phase-out the use of 38.8 MT of HCFC-141b by converting to c-
pentane technology at the Akadabi Steel Company for Insulation panels and thereby contributing to
the country’s obligation to freeze the HCFC consumption by 2013 and to reduce by 10% in 2015.
Company Profile
1.2 BASELINE DATA FOR COMPANY AKADABI STEEL
Akadabi Steel was founded 1994. And it started manufacturing operations for steel faced sandwich
panels in 1996 on the discontinuous method for roof, walls in the cold room construction, building
and container industry for construction and insulation purposes.
Akadabi Steel is a member of 100% Sudanese Al Akadabi Industrial Group. (Akadabi Steel, AIP
Akabi Insulated Panels (EPS-concrete core panels), Akadabi for Transportation, Akadabi
Manufacturing for Doors, Windows & Furniture from Aluminum, Abu Altayeb Factory for High
Rising Building, Akabdabi Factory for Pre-fabricated Units.
Akadabi Steel is situated in Industrial Area of Khartoum North, Sudan
The enterprise has 130 employees from total 450 at the production of sandwich panels including
technical and managerial staff for research and development, design, manufacturing, assembly,
training, technical support, sales, marketing and after-sales services.
The only market is Sudan and all HCFC-141b based products are for Sudan’s own consumption.
Address:
Akadabi Steel.
Khartoum North
Sudan
Owner: Al Akadabi Industrial Group
Contact person : Abd EL Rahman A. K. Ahmed
Phone: +249 185 322886, Fax: +249 185 320883
Cellular: +249 9 12311207
Email: arg5670@yahoo.co.uk
Equipment Make/Model S/N Capacity Date of Action Disposal
installation Proposed plan
HP foaming Elastogran, n.a 1,500 g/s 1997 Replacement Scrap
dispenser Germany 160 kg/min by means of
adding second
mixing head to
the OMS
Impianti
Ecomaster 200
HP foaming OMS 2268 180 kg/min May 2007 Retrofit polyol N.A.
dispenser Impianti side for the c-
Ecomaster pentane duty
200
3
Sandwich Paul Ott 7142 Retrofit and to N.A.
panel press 300K 120-S be moved to
5 day lights 3 m x 1.5 m work in new
position and
served by the
second mixing
head of OMS
Ecomaster 200
Sandwich 450 m2/shift Retrofit N.A
panel press
1 + 1 12.5
m
The production line 1, which was assembled in the year 1997, is utilizing Elastogran GmbH 160 kg /
min high pressure foaming machine with Paul OTT 5 daylight press for the production of sandwich
panels of size up to width of 1.5 meters, and length up to 3 meters. Main use is for the insulation slabs
sandwich panels for the portable cabinets with facing materials of 0.4 – 0.6 pre-painted steel sheets
and MDF boards up to 12 mm. One shift (8 hrs) production capacity is about 300 m2.
Important note to the equipment supplier!
This production operation is to be re-positioned according to the attached lay-out drawing. Re-
positioning work is a responsibility of the beneficiary company, only positioning of the new mixing
head is a responsibility of the equipment supplier.
The production line 2, is utilizing OMS Impianti Ecomater 200 foaming machine and 2 by 2 Orto
press with two scissor elevator tables.
4
Starting with a roll-forming unit the pre-coated steel sheet (0.4 – 0.65) mm is formed up the required
length 12.5 m and of 1.2 m wide.
After forming the steel sheets, the upper and lower sheet metals are conveyed and assembled
manually into a panel on 2 + 2 ORMA press. Plastic separators are inserted to ensure the correct panel
thickness of 40mm, 60 mm or 80 mm.
5
After assembly of the sheet metals from the both ends of the press, the empty panels are taxied into a
2 x 2 press, and simultaneously two already cured panels are moved out from the both ends of the
press.
Foam is injected using a high pressure Impianti OMS Ecomaster 200 foam dispenser with an output
of up to 180 kg/min, and a mixing head pressure of 130-150 bar.
6
Machine tanks of polyol and MDI have 250 l capacity each.
The de-molding time ranges between 15-20 minutes to one hour depending on the panel thickness.
For PU steel sandwich panels a two-component PU polyol / MDI system is used with HCFC 141b
blowing agent (23 parts by weight of polyol). A catalyst, flame retardant, foam stabilizer (silicon
stabilizer) and small amount of water are also included. The mixing ratio of polyol mixture and
isocyanate is 1 to 1.2.
The foaming machine is equipped with two day tanks, each with a capacity of 250 liters, which are
filled by separate pumps from standard drums.
The density of the rigid PU foams produced depends on the exact product and ranges between 39 and
45 kg/m³.
The table below summarizes the annual production of PU steel sandwich panels and HCFC-141b
consumption at Akadabi Steel:
2006 2007 2008 2009
m2 m2 m2 m2
Sandwich panel 97,436 109,401 143,590 140,000
and insulation
slab production
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2. SCOPE OF SUPPLY AND TECHNICAL SERVICES
To convert the production process at Akadabi Steel from the use of HCFC 141-b as blowing agent to
cyclopentane, it is requested that a bidder propose an overall concept of the conversion including
safety maintenance as well as training of personnel manuals and complete package of necessary
equipment and instrumentations, to convert the whole existing production facilities, including
blowing agent storage area, to the use of cyclo-pentane as the auxiliary blowing agent.
2.1 Foaming equipment for Akadabi Steel
Note: The offer has to be structured as itemized below (five components/areas). Each item has to be
separately priced:
1. Retrofit of the existing Ecomaster 200 high pressure machine s/n 2268 for the cyclo-pentane
foaming duty;
2. Additional mixing head to serve the 5-daylight press;
3. Safety system and safety related modifications;
4. Pentane storage and supply system
5. Ventilation system for the wet and dry parts
No 1 (one) complete retrofit package of existing foaming machine ECOMASTER 200 unit for
the pentane duty including at least components as described below to be purchased.
2.1.1 Outline specifications of the foaming unit
The retrofit package of the foaming unit should be designed in such a way as to safely meter, mix and
pour two component polyurethane systems using Isocyanate and polyol blend containing c-pentane as
the auxiliary blowing agent. The special design of the machine must reflect special features of pentane
blowing technology signified by flammability of the blowing agent.
The specifications should refer to materials suitable for the following production parameters:
Polyol/pentane to isocyanate ratio (wt/wt) 1:1
Polyol blend viscosity (24º C) mPas <1000
Isocyanate viscosity (24º C) mPas 100 - 300
Cream time (sec) 14 - 30
Full rise time (sec) 140 - 180
Suction cabin, which will encapsulate the polyol / pentane high pressure metering line, it can
be common with the pentane premixing unit;
A double speed ventilation group to be connected to the suction enclosure in order to ensure
adequate airflow in the enclosure;
Foaming machine grounding in order to avoid any sparks between machine components
Modification of electrical and mechanical parts to meet the safety standards
Following parts are foreseen to be added:
o EEx-i capacitance loading level and relative barrier;
o Supermax EEx-i level and relative barrier;
o EEx-i proximities with relative barriers
o Nitrogen pressurization system;
o Pentane sensors
o Fail safe valves
The dispenser should be able to serve two mixing heads after the retrofit for the pentane duty.
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Additonal mixing head
1 (one) self-cleaning mixing head on the existing ECOMASTER 200 high pressure foaming machine
with relevant mechanical, electrical and software modification, the rigid and flexible pipeline, the
flow valve and the oil accumulator to facilitate foaming operation on the Paul OTT 5-daylight press.
This mixing head is to serve second press, which is situated about 42 meters from the existing
foaming machine (see attached lay-out drawing).
High pressure impingement head sized to foamed volume/mass requirements, complete with
hydraulic servo-valves for head opening and closing cycles, polyol and isocyanate nozzles with
adjustable pouring pressure and nozzles holder.
Premixing unit
One pentane premixing unit adjacent to the foaming unit or c-pentane drum storage must be supplied.
It must be equipped, with connecting inlet piping and necessary distribution (outlet) piping.
The unit must be enclosed and equipped with appropriate ventilation system.
2.2 Safety system and safety related modifications – OPTIONAL
The supplier is requested to provide:
- detailed project of the safety concept and installations of all safety elements
- detailed drawings for safety installations including pentane storage area and pentane
supply (low pressure side).
- safety maintenance documentation and manuals
Notes
I.
The selected supplier must re-examine and properly classify each potential explosion zone in the
entire plant in the conformity with international safety and fire fighting regulations
II.
Specified works and components of the safety system may be ensured through the local
purchase and subcontract.
This modality has to be clearly indicated in the proposal! The name, full address and the
contact person of the (local) sub-supplier or sub-contractor has to be provided.
The bidder remains responsible for overall quality and safety of new installations!
Close collaboration with appointed (local) sub-supplier is a mandatory condition!
The following are the basic elements of the safety system:
a) Ventilation system in the: - production area,
- pentane storage facility and
b) Necessary, safety related civil construction works;
c) Electrical system adaptation, including ex-proofing of relevant elements and grounding of
entire plant;
d) Pentane detection and alarm system.
e) Safety System Maintenance. The document which can be presented in the format of manuals,
booklets, floppy discs or CD ROMs must contain principal elements, guidelines and
particular procedures for maintenance of whole safety system at the plant. The manual must
be tailored to the specific conditions of the factory.
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The supplier must provide necessary information on Safety System Maintenance. SSM must contain
a special safety matrix, which explains in an easy way, subsequence of necessary actions, i.e. which
detected failure must be followed by which action. The manuals on the safety action plan in
general and emergency action plan in particular must be provided in English language.
Manuals in Arabic will be assets.
2.3 Pentane storage and supply system
The following components of the blowing agent supply system must be subject of the contract:
Two (2) drum storage facilities with approx. 500 litre buffer tank. The facilities must be designed
and installed in accordance with international and local safety and security regulations.
Note
The storage facility may be manufactured locally, according to the technical drawings to be provided
by the supplier of foaming equipment. The supplier shall provide complete package of engineering
documentation (detailed project) sufficient for local fabrication and construction of the storage,
including the tank and necessary basin. Necessary fittings and special ancillaries should be provided
by the supplier.
This modality has to be clearly indicated in the proposal! The bidder remains responsible for
technical background and technical concept for quality and safety of the facility and pentane
supply (pipelines, fittings, pumps, manometers, safety detectors and connection to polyol
premix)!
2.3.1 Pentane buffer tank
The tank will be specially designed for storage of pentane, according to the physical and chemical
properties of pentane. The tank should be designed for the drum storage facility use.
The supply should also include all required flanges, pentane delivery pumps designed for explosive
liquids and gas mixtures, explosion proof level gauges and controls (including current level control),
saturators, safety valves, to avoid overfilling and over-pressure, remote operated valves etc.
Prevention against static electricity must be installed. Velocity of liquid pentane entering the tank
should be reduced to max. 6 m/s in any case.
Earthing of all equipment is mandatory.
10
Factory lay-out
11
3. GUARANTEE REQUIREMENTS.
12 months guarantee as mentioned above is requested.
Potential suppliers should have local or regional representative to be able to assure warranty and after
sale service for at least 5 years after commissioning.
Evidence about the ability for a long-term guarantee service must be submitted together with the
quotation.
4. DELIVERY PERIOD. TIME SCHEDULE
Step Completion time Responsibility
counted from
Activities
the placement of
the purchase
order
[month]
1 2 Presentation of the overall concept for the conversion Supplier in
technology. Project site preparation for conversion collaboration with
Counterpart
2 6 Delivery of necessary components and retrofitting of foaming Supplier
equipment
3 7 Installation and commissioning of the equipment and Supplier (in
ancillaries. Installation of all components of the safety system close
collaboration with
harmonization of the components supplied with the foaming appointed (local)
machine and those fabricated and erected locally. On-job and sub-supplier or
safety training as well as safety maintenance training of the sub-contractor)
and beneficiary
counterpart personnel. Test-run and start-up trials to be company
executed by the counterpart personnel under supervision of
the supplier of the foaming equipment.
4 8 Safety certification. Industrial standards verification. Supplier (in
close
collaboration with
National or
International
certification
organization.)
5 8 Spare parts for the duration of 1 year Supplier in
collaboration with
Counterpart
5. INSTALLATION, COMMISSIONING AND START-UP OF THE FOAMING
EQUIPMENT, TRAINING AND ACCEPTANCE
It is required, that the potential sub-supplier of the foaming machine will carry out installation,
commissioning, start-up trial and on site training in accordance with an agreed time schedule. The
activities should include:
Installation and connection of the foam system (including piping and electrical wiring
connection).
Test run the equipment on the system operation and relevant function.
Trial run the foaming system with the actual products.
Start actual production under potential supplier’s engineer supervision (initial operation).
The training should be provided in the course of equipment installation, commissioning and start up
trial as follows:
No of technicians trained: 3
No of operators trained: 6
Minimum duration of training: 3days
12
Beneficiary shall nominate selected technicians and operators in agreement with the supplier.
The training must include the following basic activities:
Introduction of the equipment and system.
Explanation of the various circuits of the equipment including electrical, hydraulic and
component circuit.
Basic maintenance and repair work.
Safety procedures
Safety maintenance of equipment
Technical documentation and Spare Parts
Catalogues of the equipment, including technical specifications, operation manual, list of spare
parts, assembling instructions, etc. in English, should be organic part of supply.
The set of consumable and most wearing and tearing parts for at least one year of equipment
operation (guarantee period) must be an organic part of the offer (supply or sub-supply).
Also the list of equipment elements, spare parts and warranty services which might be required
after 12 months of standard guarantee period should be specified based on the supplier/sub supplier
best experience in operating the equipment assemblies and subassemblies including its cost break
down must be included in the offer.
Certificate of Acceptance, duly signed by the counterpart enterprise, supplier of equipment and
UNIDO has to be provided by the supplier, to accomplish the contract.
Safety certification
In accordance with the common practice of safety certification of similar industrial plants, the national
safety certification (e.g. fire fighting department) organisation should be involved in the project
execution from the beginning of the process.
6. RECOMMENDED TABLE OF SCOPE OF SUPPLY
UNIDO RFP reference No.
Scope of supply
UNIDO REQUIREMENTS TO BE COMPLETED BY THE INVITEE
Item Name and required parameters Quantity unit price total item price Compliance Remarks**)
currency currency yes/no
Equipment, parts, supplies in 3
I. accordance with Para 2 components
Installation, commissioning in
II. accordance with Para 5 1 set
Sub-total:
III. Cost of transportation 1
IV. Cost of Insurance
Total price:
**)if not compliant with UNIDO’s required parameters,
13
the invitee must indicate his parameters in this column
Evaluation criteria:
- Full compliance of proposed equipment with technical specs as outlined in Chapter 2 of the TS
- Minimum three years reference list of similar projects.
- Compliance with the proposed time schedule
- Availability of the representative office including technical facilities in the country or the region
to be able to ensure long term services.
- One year warranty on critical technological parts to be ensured as a minimum.
