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A1 - A7 Dieffenbacher Technical Offer 387151 - 01 20210601
A1 - A7 Dieffenbacher Technical Offer 387151 - 01 20210601
: 387151-21-01
Buyer / Project: TAN VIEN MDF Hanoi
Annex 1: Basic Technical Data Date: 2021-06-01 Page: 1 of 29
Annex 1
Basic Technical Data
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A1 BASIC TECHNICAL DATA 20210601.DOCX
Quotation - No.: 387151-21-01
Buyer / Project: TAN VIEN MDF Hanoi
Annex 1: Basic Technical Data Date: 2021-06-01 Page: 2 of 29
Remarks:
All values indicated under “Basic Technical Data” are only basic values for
the design of the plant and are in no case warranted properties or
warranties. Warranties and properties of the plant are specified in Annex 4.
The mentioned wood moistures always refer to the oven-dry sample (b.d.).
That means that with a sample weight of 100 kg and a wood moisture of
100% these are 50 kg dry weight of wood and 50 kg water (50 kg water are
100 % referred to 50 kg dry weight of wood).
Abbreviations:
- b.d. = bone dry
- STP = standard temperature (273,15K) and pressure (1,013 bar)
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A1 BASIC TECHNICAL DATA 20210601.DOCX
Quotation - No.: 387151-21-01
Buyer / Project: TAN VIEN MDF Hanoi
Annex 1: Basic Technical Data Date: 2021-06-01 Page: 3 of 29
1.1 Product
MDF/HDF boards,
produced in an industrial process,
according to the industrial standard EN 622, edition Sept. 2003.
1.2 Application
The proposed technical plant concept is designed for the production of high-
quality MDF/HDF boards for a broad range of application.
The glued MDF/HDF boards are suitable, among others, for the subsequent
application areas:
- In the housing construction as wall-, ceiling- and roof covering,
as non-supporting elements, hidden application
- In the housing construction as wall-, ceiling- and roof covering,
as non-supporting elements, visible application
- In the housing construction as floor panels/laminate (tongue and groove)
- In the furniture construction as laminated board
These MDF/HDF boards can either be used in an untreated or laminated
form (with impregnated paper).
1.3 Properties
Provided that the raw material to be made available by the Buyer
corresponds to the minimum quality requirements, the properties according
to the industrial standard EN 622, edition 2003, can be fulfilled.
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2. General data
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- Local operations are only for equipment, repairs and maintenance and
dispose of additional noise prevention signs.
- Exceptions from this are areas which are only sporadically used during
the normal production process.
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3. Plant capacity
Basic data:
- Technologic press length 55.910 mm
- Board width, net 2.460 mm
- Thermal oil flow temperature, primary side min. 290 °C
- Mat temperature at press infeed
● min. + 40 °C
● max. + 55 °C
- Working hours per day 22,5 h
- Production speed max. 1.800 mm/s
Thick- Heating
Sanding Density Production Plant
Typ ness time
allowance approx. speed capacity
net. factor
1)
Restrictions of the press design speed v max. 1.800 mm/s
2)
Restrictions due to fiber throughput design max. 48.000 kg b.d./.h
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Basic data:
- Technologic press length 55.910 mm
- Board width, net 2.460 mm
- Thermal oil flow temperature, primary side min. 290 °C
- Mat temperature at press infeed
● min. + 40 °C
● max. + 55 °C
- Working hours per day 22,5 h
- Production speed max. 1.500 mm/s
Thick- Heating
Sanding Density Production Plant
Typ ness time
allowance approx. speed capacity
net. factor
1)
Restrictions of the guarantee speed v max. 1.500 mm/s
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4. Plant parameter
Chip storage
- Volume chip silos approx. 4 x 600 m³
- Output capacity approx. 200 m³/h
- Bulk weight conveyed goods 140 kg b.d./m³
ClassiScreen
- Capacity 320 m³ b.d./h
51.000 kg b.d./h
Bulk weight chips approx. 140 kg b.d./m³
- Screen fractions
● Fines 0 - 5 mm max. 10 %
● Chips 3 - 30 mm max.100 %
● Oversized > 30 mm max.5 %
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- Exhaust gas
● air volume
o at standard conditions, approx. 571.200 m³/h STP wet
o at actual conditions, approx. 730.500 m³/h wet
● temperature 74 °C
● moisture content 0,162 kgH2O/kg
● density 1,188 kg/m³ STP wet
● dust content ≤ 50* mg/m³ STP wet
*measured without using exhaust air from pneumatic systems
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Line speed:
- production speed , max. 1.800 mm/s
Test strip cutting is possible when only one or two saw units are used for
cutting master panels
Cycle times:
- Master panel due to pre-stacking station. 2,5 s
- Master panel length at maximum press speed, min.
1.800 mm/s x 2,5 s = 4.500 mm
- Press speed at minimum master panel length, max.
3.600 mm / 2,5 s = 1.440 mm/s
- cooling wheels with single panels, min. 8 s
- cooling wheels with pre-stacked panels 12 s
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Note: Cooling efficiency is under standard 100 s/mm with some short panel
lengths.
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Remark: With the OPTION of the second STS first in first out is possible.
Feeding station 1
- Stack height, max 4.000 mm
- Stack weight, max. 50.000 kg
- Feeding cycle-time, min. 2,4 s
Feeding station 2
- Stack height, max 1.000 mm
- Stack weight, max. 12.500 kg
- Feeding cycle-time, min. 2,4 s
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Sawing:
- Book height max. 200 mm
- Front trim width (including kerf) 20 - 80 mm
- Back trim width (including kerf) 20 - 40 mm
- Longitudinal cutting dimensions 610 - 1.245 mm
- Cross cutting dimensions n x (1.830 - 4.100) mm
Stacking
- Stack height, max. 1.200 mm
- Stack weight (double stack), max. 9.000 kg
- Lower stack heights are possible. But depending on production speed
this may reduce the line capacity.
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Cutting patterns
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Stack data:
- Stack width 610 – 1.245 mm
o Special packing mode 2 x 610 mm
- Stack length 1.830 – 4.100 mm
- Stack height 500 – 1.200 mm
- Stack weight, max. 4.500 kg
Strapping machines
- Automatic stretch foil wrapping 1 -
- Automatic crosswise strapping 1 -
Crosswise strapping
- Strapping belt width approx. 19 mm
- Number of straps 3-5 -
- Strapping cycle-time / strap, min. 20 s *)
- Bottom runners (unbroken top and bottom) 80 x 80 mm
- Bottom sticks used with every stack yes -
- Number of cassettes for bottom sticks 4 -
- Top corner protector material cardboard -
- Top corner protector size L 5x50x50 – 100 -
*) Excluding stack conveying time
Strapping capacity
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Main features:
The firing system consists of:
- Grate firing
- Dust injection
- Granulate injection
- Thermal oil heater with soot blowers
- Cyclone group for de-dusting
- De-ashing system
Fans and transfer pumps of the thermal oil system are equipped with
frequency converters to reduce the electric power consumption.
Heat consumption:
- Flue gas for dryer, 350 °C 33,3 MW
- Thermal oil:
● Steam generator 23,4 MW
● Sifter 1,7 MW
● Press 6,8 MW
● Thermal oil total 31,9 MW
- Total 65,2 MW
- Thermal oil
● Flow temperature 285 °C
Heat Generation:
- Reciprocating grate, ~ 65,7 m²
Acc. wood moisture
● 60 % dry basis; 750 kW/m² 49,3 MW
● 125 % dry basis; 700 kW/m² 46 MW
- Sander dust 3 x 10 MW
- Granulate injection 1x5 MW
- Total combustion maximum (limited) 65,2 MW
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Fuel Specification:
Grate firing:
Bark, chips, recycled wood waste in a homogeneous mixture with the
following specifications:
- Ash softening temperature > 1.150 °C
- Particle size distribution
● Main fraction 25 - 50 mm > 80 %
● Max. size 150 x 50 x 50 mm < 10 %
● Dust < 5,0 mm < 10 %
- Moisture content 60 - 125 % dry basis
- Bulk density approx. 230 - 400 kg/m³
- Ash content < 5 % wet basis
- Chlorine content < 400 mg/kgdry
- Sulphur content < 300 mg/kgdry
- Nitrogen content ≤ 0,15 % dry basis
Granulate injection:
- Ash softening temperature > 1.250 °C
- Particle size
● Max. size < 5,0 mm 100 %
● Main fraction < 3,0 mm 98 %
- Moisture content < 10 % dry basis
- Average lower heating value 16,7 MJ/kg
- Ash content <1 % wet basis
- Chlorine content < 400 mg/kgdry
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- Acacia
● Logs 20 – 80 %
● Slabs, up to 10 %
● Foreign chips, up to 10 %
5.3 Paraffin
A product of Sasol shall apply as the reference emulsion. The reference
emulsion must be available in case of problems with the processability, the
physical-mechanical properties and / or the plant capacity.
The use of the replacement emulsion provided by the Buyer has to be agreed
upon with Seller.
5.4 Hardener
Optionally, as hardener may be used ammonium chloride (NH4CL),
ammonium nitrate (NH4NO3) or ammonium sulphate (NH4)2SO4).
Dry content 15 - 40 %
5.5 Buffer
Depending on the glue used and / or the processing temperatures ammonia
or hexamethylentetramine may be used as buffer.
5.6 Water
The continuous and sufficient provision of the line with processing, cooling
and extinguishing water in the required quality must be ensured.
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5.10 Lubricant
For the lubrication of the CPS press chains, a special lubricant oil of
company CASTROL, LUBCON or KLÜBER shall be used.
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7. Personnel requirement
Remark:
- The following indications are based on experiences made with similar
plants and require that the personnel have made the relevant
experiences in this production process.
- The personnel for administration, maintenance works, cleaning and
guard service is not mentioned.
- The actual personnel requirement can vary because of local conditions.
Shift Shift
-- -- Total
I II
Debarking/
2 2 -- -- 4
Chipping
Sub-total 5 5 -- -- 10
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Shift Shift
Shift III Shift IV Total
I II
Shift leader 1 1 1 1 4
Chip feeding/-storage/ -
2 2 2 2 8
cleaning
Debarking 2 2 2 2 8
Refining 1 1 1 1 4
Control room 2 2 2 2 8
Productions control 2 2 2 2 8
Sanding /
1 1 -- -- 2
raw board storage
Forklift operator 2 2 2 2 8
Spare man 2 2 2 2 8
Shift repairman 2 2 2 2 8
Shift electrician 2 2 2 2 8
Shift laboratory
1 1 1 1 4
technician
Sub-total 21 21 21 21 84
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Shift Shift
-- -- Total
I II
Chief of dispatch 1 1 -- -- 2
Forklift operator 1 1 -- -- 2
Dispatch worker 1 1 -- -- 2
Sub-total 3 3 -- -- 6
Shift Shift
-- -- Total
I II
Production management 2 -- -- -- 2
Mechanical workshop 4 -- -- -- 4
Electrical workshop 2 -- -- -- 2
Chief storekeeper 1 -- -- -- 1
Grinding shop 2 1 -- -- 3
Chief of laboratory 1 -- -- -- 1
Laboratory assistant 1 -- -- -- 1
Sub-total 13 1 -- -- 14
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Wood yard 5 5 -- -- 10
Production line 21 21 21 21 84
Dispatch 3 3 -- -- 6
Miscellaneous 13 1 -- -- 14
Total 42 30 21 21 105
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Annex 2
Seller's Scope of Supply
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Annex 2 contains mainly a list of Seller’s Supply. Items are marked differently
if they deviate in the type of supply.
The following abbreviations are used in the machine specification:
ENG – Engineering
For these items DIEFFENBACHER will supply engineering only. The level of
engineering that will be provided is dependent upon the type of equipment.
OPT - Option
Not included, but equipment offered by DIEFFENBACHER with a change in
price.
EXT – Extension
Not included, but the equipment can be retrofitted at a later project stage.
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Annex 2, Section 70.000: Electrics and Automation Date: 2021-06-01 Page: 1 of 22
___________________________________________________________________________________________________
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CONTENTS
1. Technical Data
2. Function
3. Overall Systems Description
4. Platforms and Components
5. Equipment to be controlled
6. Physical Supply Units
7. Design Criteria
8. Ambient Requirements
9. Interface Definitions
10. Functions in individual Process Sections
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1. Technical Data
Line Voltage:
- Low voltage 3 x 380 V 50 Hz
- For dryers with frequency controlled main fan drive one 690 V feed each
is required.
The low voltage power supply shall be limited to and protect a maximum
short circuit current of effective 48 kA.
Permitted Fluctuation:
- Line voltage <±5 %
- Line frequency <±2 %
- Harmonics <7 %
Control Voltage:
- as general control voltage (for field devices etc.) 24 VDC
- for motor starters and as control power source 220 VAC
Language:
- English (Nameplate inscriptions, etc.)
- Operating interface HMI in English
- Operating manual in English
- Maintenance manual in English
- Program listings in English
- HMI (Visualization) in English
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2. Function
Control and automation of specified process sections resp. equipment
according to the list of main functions below:
- Control logic for equipment and process
- Process control loops
- Speed control for variable speed drives
- Centralized operation and monitoring in control room
- Local operating station provided for Wood Yard and Storage and from
Sanding downstream, if in scope.
- Color graphic process visualization (HMI)
- Trending of process values
- Alarm messages in clear text on screen and printable
- Local jog mode operation for test and maintenance
- The central control room is equipped with color graphic PC HMI monitors
ergonomically located on an arrangement of computer desks.
- Local control stations are reduced to the necessary minimum, those are
designed according to the requirements as control panels or even with
computer monitors. Operator stations in the field, especially in chipping
and flaking are designed as industrial touch panel computers; in the central
control room overview screens for the areas concerned are provided which
are integrated in the HMI of material preparation.
-
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- Field devices are connected to the PLC's by bus technology and local I/O
modules at the equipment in order to reduce field wiring and improve
maintainability/trouble-shooting. Central PLC design might be considered
where short distance cable runs permit.
- The power control part for motor drives is provided normally in form of an
arrangement of control cubicles (MCP = Motor Control Panel) with main
infeed switches, motor starters, fuses, drive controllers and associated I/O
modules etc. All of those are internally pre wired and shop tested
or
as standardized modular Motor Control Centers (MCC), for example
according to North American standards, supplied either by the Seller or by
the Buyer or by others. The version, provided, as well as the supplier is
specified under "Physical supply units" and/or "Buyer's Scope of Supply".
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Mechanical
Telemecanique #
limit switches
Optical switches Sick , ifm, Leutze
#
(position, level, engage) acc. to functional requirements
Proximity switches
Pepperl & Fuchs, ifm #
(inductive)
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5. Equipment to be controlled
- Included in the scope is the control of all equipment as well as the
related safety equipment according to the Dieffenbacher Safety Layout
listed in this project as Seller's equipment supply, if not differently
specified.
- There under the following items have a control system from the
equipment manufacturer acc. to its design standard included in the
equipment package. The Seller ensures consistency and integration into
the overall plant control concept with regard to interfaces and systems
platforms:
● Chip washing (if option is chosen)
● Refiner (if option is chosen)
● Sanding machine (if option is chosen)
●
- Apart from the Seller's scope of equipment supply the following items
which are mechanically provided by others are controlled by this system:
● None of such
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Supplier
Electric Items
Buyer Seller
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Supplier
Electric Items
Buyer Seller
- application software #
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Supplier
Electric Items
Buyer Seller
1 PC engineering station
c/w bus connection and PLC programming #
license.
Installation material
Supply of material for electrical field
installation of seller supplied electrics and
control system to equipment, consisting of:
- cable trays #
- conduits #
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Supplier
Electric Items
Buyer Seller
- cable glands/bushings #
7. Design Criteria
- Internal mounting and wiring of control cubicles/panels according to
Seller's standard; completely pre wired and shop-tested, suitable for
reliable operation and easy trouble-shooting. Wire marking included.
- Motor control power circuits include fuses per group of smaller motors,
circuit breaker and contactor. Starters for bigger drives may have
fuseless circuit breaker protection or one set of fuses per drive and
overload protection by over current relays.
- Motor starter contactors for low voltage drives are powered with 230 VAC
via interposing relay units at the contactor. The interposing relays are
connected to 24 VDC PLC outputs.
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- Identification numbering system for control areas and groups, devices and
locations according to Seller's standard, based on DIN/EN 81346-2.
- Programming of PLC and HMI including program and data file structures
as well as communication according to sellers standard.
The right of changes in order to keep track with the state of the art is reserved.
Control systems from equipment package suppliers may deviate partially.
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8. Ambient Requirements
a) Operating conditions:
- Inside control rooms: max. 30 °C / 86 °F
- For control cabinets and panels in process areas and electrical rooms:
● max. 35 °C / 95 °F on 24 h - average, short-term max. 40°C / 104°F
● min.-inside temperature + 5°C / 41°F
- Humidity:
● max. 90 % at 20°C / 68°F, non-condensing
● max. 50 % at 40°C / 104°F, non-condensing
- Prevent sudden temperature drop below dew-point that would create
condensation. Provide suitable air conditioning where required.
- Standard design is suitable for an altitude up to 1000 m/3280ft. above
sea level.
c) General remark:
- Keep all electric/electronic equipment dry; prevent any access of water
or other liquids to it.
9. Interface Definitions
Interfaces:
- In case interfaces to systems not supplied by the Seller are
requested/required, a binding and written agreement is to be made for the
hardware and software design prior to the implementation.
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Grounding:
- As part of Buyer´s scope a common ground bus, throughout the facility
shall be provided with adequate connecting points in all areas. Buyer´s
scope shall also include ground connections to all Seller supplied electrical
cubicles. Grounding cabling from these points to Seller supplied
equipment is considered part of the field installation. Responsibility is given
in the contractual definitions of scope of supply and services.
Existing Installations
- In case of supplies and/or services for modification or extension of existing
installations, changes, modifications etc. to existing components and
systems are excluded from the Seller's scope, unless expressly included
in the scope of supplies and services.
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70.073 - - PRODACON
Description of function:
This module of PRODACON acquires all process values plant- wide and
stores them in a central database for further processing and analysis. All data
are stored in the system for a period of approx. 3 months as a minimum.
Trending:
A powerful trending functionality, developed according to the requirements
and in cooperation with customers quality control and maintenance
managers, provides freely configurable trend screens for groups of values in
actual, as well as in historical mode. It serves as a tool to analyze the process,
to discover any irregularities with there reasons, to increase efficiency of the
whole production process and optimize to consistent board quality.
Grouping of values can be chosen by the operator in up to approx. 10 vertically
stackert fields and 1 or 2 horizontal axis. Individual auto scaling and manual
scaling to engineering units is available for each of the selected values.
Selecting the values is user friendly by clear text listing and grouping
according to the structure of the plant.
Timeframe selection, zooming and expanding functions are available and
easy to use.
All trending screen configurations can be named and stored in the database
for future use and to be modified to create new ones.
The optional feature as Web Client allows the use of the trending functionality
at any PC workplace in the network of plant automation.
Any screen image is available for printout.
All data are stored in open database format and therefore available for further
processing. If required, lab data may be integrated.
Process Vector:
To create the process vector, PRODACON selects from the data acquired,
those which are most significant to the board properties. These values are
traced through the production process according to the material flow and build
a set of dedicated data which represent the process variables, directly linked
to the board (i.e. a lab cut) at the press outfeed. Lab test results may be
integrated in the modules database and functionality as required.
The vector data are available as data files and may be printed as a hardcopy
on demand
A trending function is available for the vector data as well.
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Description of function:
This module acquires the raw material consumption values from specified
plant areas and includes, if data are available, the values of consumed energy.
The amounts of panels produced, related to production batches and to time
periods are counted as well and accordingly calculated into production
reports. If required, further data such as variable cost may be integrated upon
agreement.
Further reported data are uptime, downtime statistics with reasons related, the
amount of lost production by reasons of rejects, blown boards, boards out of
thickness tolerance etc.
Further Evaluations are possible, even by the end user, since the reports are
provided in standard office software format (Excel) and available from open
data base.
If required, data can be provided for transmission to customers ERP system
(interface not included).
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With that a service spectrum with following content for the Buyer is provided:
- Remote maintenance (search of faults, trouble shooting, remote access
to signals and information)
- Remote diagnosis
- Remote conference (online conference, online meetings)
- Remote advisory service (technological and process advice, product
design)
- Remote operation, remote control (program support, up-download,
system service)
- Remote support (process support, operator assistance, system backup).
Scope of supply /
design: Additional software and hardware components to be applied for the service
spectrum:
- Multimedia-based peripheral equipment (audio and video components)
- Network technology
- System programs
- Communication software
- Computer technology
- Internet Version: Firewall, Virus scanner and VPN-technology
To be supplied by Buyer:
Direct Internet connection (xDSL, e.g. ADSL, SDSL, HDSL, T1 etc.) with min.
1024 kbit/s (1 Mbit/s) down and upstream
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Annex 6
Project Schedule
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1 General
Any subsequent change of the delivery specification and/or any delay on the
part of the Buyer in the fulfilment of his financial obligations will cause a new
definition of the delivery period. The same shall apply if the Buyer fails to
provide his supplies and services in time or in full.
A countersigned layout drawing as well as a building plan in scale have to be
an integral part of the signed contract.
2 Dates
All dates mentioned in this paragraph refer to the effective date of the contract.
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Annex 7
Drawings
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