FUNCTIONNAL SPECIFICATION FOR

GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 1 of 10
P999 B 02 GN FS 001 B

FUNCTIONNAL SPECIFICATION FOR

GRAIN MILLING

D
C
B 03/03/2015 Up to date according to comments SZ CB JT
A 20/01/2015 First Issue SZ CB JT

Rev. Date Of Issue Description Prepared Checked Approved

 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 2 of 10
P999 B 02 GN FS 001 B

TABLE OF CONTENTS

1. GENERAL .......................................................................................................................................3
1.1. Purpose of this Functional Specification ................................................................................3
1.2. Main climate data .............................................................................................................................3
1.3. Noise......................................................................................................................................................3
1.4. Dust emissions ..................................................................................................................................3
1.5. Electricity ............................................................................................................................................3
1.6. Compressed air .................................................................................................................................4
1.7. Standard and codes .........................................................................................................................4
2. DESIGN PARAMETERS .............................................................................................................. 6
2.1. General design and manufacturing ..........................................................................................6
2.2. Operating parameters ....................................................................................................................6
2.2.1. Raw material..........................................................................................................................6
2.2.2. Flour outlet .............................................................................................................................7
2.2.3. Process description.............................................................................................................7
2.2.4. Automation.............................................................................................................................8
2.3. Documentation .................................................................................................................................8
2.3.1. Technical Documentation ................................................................................................8
2.3.2. Maintenance Documentation....................................................................................... 10
 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 3 of 10
P999 B 02 GN FS 001 B

1. GENERAL

1.1. Purpose of this Functional Specification

The purpose of this document is to outline the main requirements for a grain milling
unit of a new Bioethanol production plant project.
The supplies and services described in this document are non-exhaustive and are to be
understood as minimum requirements;

1.2. Main climate data

Min / max absolute temperature : -27 / 44 C

Min / max temperature (average on 60 years) : -13 / 42 C

Relative humidity : 23 to 75%

Design wet bulb temperature : 20.5 C

Altitude : 1362 m

Seismic conditions : Zone 3 with A=0.30 (A=Base

Ground Acceleration) according to Iranian Code for Seismic Resistant Design of
B Buildings (STD2800, 3rd Edition)
[
T Snow load design : 150 kg/m
a
p Wind : 90 km/h at elevation + 10 m
e
1.3.z Noise
Set of equipment : < 85 db(A) at 6m radius from set
u
n Individual equipment : < 85 db(A) at 1m from equipment
e
At fence of the factory : < 45db(A)
c
1.4.i Dust emissions
t Dust emissions have to be limited to 50 mg/Nm3 in exhaust air
a
1.5.t Electricity
i Electrical power LV : Supply to switchboards 3 phases (TNS
o system)
n
B Nominal Voltage : 400 V +/-5%
[p
T
r
ai
 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 4 of 10
P999 B 02 GN FS 001 B

Nominal Frequency : 50 Hz +/-2%

B Control Voltage : 230 VAC + 24VDC

[
T Control & Automation:
a o Analogue signals : 4 20 mA
p
o Digital signals : 24 V DC
e
z o Auxiliary controls : 24 V DC
o Solenoids valves : 24 V DC
u
n Network connections
e o for instruments : HART or profibus PA
o for small local controllers : profibus DP (or profinet)
c
i o for standalone control systems : Modbus TCP/IP
t o for connections to plant network loop : fibre optic
a
1.6.t Compressed air
i
Instrumentation air (dry and oil free)
o
n Nominal / max operating pressure : 6 / 7 bar g.
Dew point : -40C at 7 bar g.
p
r Air purity : acc. ISO 8573-1 class 2-2-2
i Free of oil : < 0.1 mg/m3
s
1.7.e Standard and codes
d The equipment will comply with the following standards (or equivalent):
a
n Piping : ANSI B36-19
s
Flanges : ANSI B16-5 CLASS 150
l Electric motors : IEC 34/72
e
Electric Measurements instruments : IEC 51
d
o Electric cables : IEC 502
c
u Pressure equipment : ASME
m
e
n
 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 5 of 10
P999 B 02 GN FS 001 B

Dust hazardous area : ATEX zone 21 (Directive EC94/9)

All codes and standards applicable in Iran

Design, selection and installation of electrical systems and equipment shall be in

accordance with the following:

design criteria specification

Equipment technical specifications
Data sheets
Drawings and other documents
I.E.C. standards
CENELEC publications
B UTE, BS, when I.E.C. publications have not yet been issued
[
All equipment shall conform in design, materials, installation and performance with the
T
appropriate sections of the latest editions (with amendments) of the relevant I.E.C.
a
standards and CENELEC publication. Any equipment designed or built in accordance with
p
standards, regulation or codes other than I.E.C. standards or CENELEC publication, even
e
when equivalent, and any waiver to this specification shall be submitted to client for
z
approval.
Detailed specifications for supply, installation, testing and commissioning of each category
u
of equipment shall be produced and submitted to client for approval.
n
All drawings, calculations and documents shall be in accordance with IEC standards and
e
submitted to client for approval.
c
i
t
a
t
i
o
n

p
r
i
s
e

d
a
n
s
 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 6 of 10
P999 B 02 GN FS 001 B

2. DESIGN PARAMETERS

2.1. General design and manufacturing

Attention will be paid to the fact that the plant is located in a seismic area. All equipment
must be firmly anchored.
Attention will be paid to the fact the unit will be in a dust hazardous area. All equipment
must be compliant with the ATEX norm (Directive EC94/9) and all required safety
protections such as explosion vents must be implemented.

The milling unit shall be located in a dedicated concrete building or at least in a structure
with a roof and closed with cladding. The height must be enough to have gravity transfers
of products between grain and flour. Available space on ground for the whole unit is 20 m
x 35 m.

2.2. Operating parameters

The plant will run continuously 24h/day and 345 days/year.

2.2.1. Raw material

The main raw material processed in this unit will be wheat with the characteristics
summarized in the following table:

Composition Composition
- Based on Dry Substance for tender
% wt. on dry matter % wt. / total
Starch (fermentable) Min. 67,6 %wt. on DM Min. 60-62 %
Proteins 7 %wt. on DM 6,2 %
Fats and Oils 4.4 %wt. on DM 3;9 %
Ash 1.3 %wt. on DM 1.13 %
Tannin - -
Crude Fibers and other
19,7 %wt. on DM 17;5 %
Solubles
Total 100 % 89 %
Humidity 11 % 11 %
Total - 100 %

Nevertheless the unit must be able to process other raw material such as barley, sorghum
and corn or mix of them.
 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 7 of 10
P999 B 02 GN FS 001 B

2.2.2. Flour outlet

The purpose of this unit is to deliver to the liquefaction unit flour with the following
characteristics:

Same composition than the raw material (no bran separation)

Design flour flow rate = 26 000 kg/h

Flour particles size distribution:

max 1500 m
90% > 150 m
50% > 500 m
10% > 1000 m

2.2.3. Process description

The milling unit technology has to be hammer mills type.

The following process steps have to be part of the milling unit:

- Grain buffer silo (2 hours retention time minimum)

- Inline grain cleaning
- Grain inline weighing (mass flow transmitter)
- Hoppers
- Hammer mill(s) protected by magnet trap
- Screens / sieves to ensure the specified particles size distribution
- Dust aspiration system with filters
- Flour buffer tank (minimum 1 hour retention time) equipped with extraction screw on VFD
to adjust the flour requested by liquefaction unit.

All required conveyors, screws, bucket elevators, instrumentation must be part of the
package.
B Earthing and Grounding protection system to protect any electrostatic explosion must be
[ part of the package.
T
a A stand-by hammer mill shall be proposed as an option for:
p - Maintenance purpose
e - Ability to keep the nominal flow rate in case of harder raw material processed such as
z barley.

u
n
e
 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 8 of 10
P999 B 02 GN FS 001 B

2.2.4. Automation
The unit has to be automatized as much as possible. The liquefaction automation will
require a certain flow of flour that the milling unit will have to provide.

2.3. Documentation

2.3.1. Technical Documentation

Documentation for Local Authorities in English language

Technical Documentation available on CD shall include (but is not limited to):

o Principle and process description of the different sections. Description of

further important flow parameters, e.g. temperatures, dilution factors,
qualities, etc.
o Starting, shut down and emergency shutdown procedures should also be
described.
o List of alarms with impact on the equipment or process
o P&IDs, containing the following information:
Equipments, Valves, Instruments, Motors,...with tagging
Piping line dimension and numbering,
Piping material classes
Fluid codes / fluid lists (nominal, min, max)
Control loops & interlocks representation and identification
numbering
Process flow indication
Battery limits: list and geographical location
Other relevant information (insulation, tracing, ...)
o Safety analysis
HAZOP
Calculations notes of safety valves, flame arrestors, vents.
o Construction qualification file, including:
QAP Quality Assurance Plan and ITP Inspection Test Plan
Welding procedure,
Qualification of the welders
Pressure test certificates, all NDT reports
 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 9 of 10
P999 B 02 GN FS 001 B

Material certificates of the plates

Material certificates of the electrodes
o Design construction file, including:
Mechanical drawing in .dwg
Calculation note
Lay-out drawing in .dwg
Definition of the ATEX zone
o Utilities requirements (compressed air, raw water, cooling water ...)
o Firefighting requirements, if any specific
o General Arrangement drawing with specific lifting requirements
o Equipment lifting and handling instructions / drawings
o Equipment list, including:
Main equipment list
Pumps list
Motors list
Valves and instrument list
Control valves list
Stop valve list
Tanks and vessels list
Piping line list

o Electrical drawings and terminal junction boxes drawings

o Functional description, including mechanical operation, curves, control
loops and interlocks
o Piping Specifications
o Valves and piping accessories specifications and drawings
o Insulation specifications
o Sub suppliers list
List of main Suppliers for:
Motors
Instrumentation (with calibration certificates)
Pumps
Control system
Boards
Compressors
Blowers
Heat exchanger
Valves and steam traps
 FUNCTIONNAL SPECIFICATION FOR
GRAIN MILLING

Contract No.

Project Title KERMANSHAH BIOETHANOL PRODUCTION PLANT PROJECT
GSZ-2014-101
Project Dis. Doc. Serial
Phase Unit Rev.
Document Number: Code code type No. 10 of 10
P999 B 02 GN FS 001 B

...

o Shipping details (volume, weight, etc.)

o Packing list
o Certificates of origin
o Performance test reports
o Procedures for chemical cleaning
o Detailed time schedule showing the important milestones (from contract
signature till FOB and for site installation and commissioning)

2.3.2. Maintenance Documentation

As additional part of the technical documentation, the package supplier shall also provide
the maintenance recommendations including:
o Maintenance manuals
o Lubrication schedule
o Spare parts lists for 2 years operation including
Supplier
Price
Part reference
The spare part list should make the distinction between spare and ware parts and shall
include a price.
The frequency at which the spare and ware parts need to be replaced.