Specifications Report - Highlighted

General Specifications Report /
Archer Daniels Midland Company Loc. No.: 05-4KV (Site Code: BG-72001)
ADM Bulgaria
North Industrial Zone
P.O. Box 239
Razgrad, Bulgaria 7200
Engineers: Andrea BRIZZI
Tommaso LONNI
Date: 28 JUL 2016

COMMENTS
The ADM Razgrad wet corn milling facility is in the development phase of an expansion project having the
following main characteristics:
Millhouse
1) Rail corn receiving (currently not used) will be modified to accept corn trucks.
2) Additional corn cleaning, weighing, and transport modifications will be required to transfer the
corn to the millhouse steeping area.
3) Grind capacity will double from 1250 to 2500 MTD; equipment will be added to all areas of mill
and feedhouse.
4) New steeps, grind mills, centrifuges (mercos), screens, starch washing, etc. will be installed in
the existing millhouse.
5) A new feedhouse area will be built that houses germ and fiber dewatering systems.
6) Adjacent to the new feedhouse they will have new germ and fiber dryers (1 each).
a. The new germ dryer will be a fluid bed and heat will be supplied by CHP TEG
(combined heat and power thermal exhaust gases).
b. The new fiber dryer will likely be a direct fire (natural gas) drum dryer – no CHP TEG
c. The old germ dryers (and possibly fiber dryer) will be removed from the millhouse area
to create space for new equipment needed for the expansion.
7) A new gluten dryer will be built adjacent to the existing gluten dryer.
a. Gluten dewatering equipment (RVF – rotary vacuum filters) will be relocated from the
existing millhouse to the new area, and new RVFs will also be installed at the new
location.
8) A new MVR evaporator for light steep water evaporation will be installed – location to be
determined.
9) There will be no capacity increase for dry starch production.
Refinery
1) Starch conversion capacity will be increased to support the additional production of fructose,
crystalline dextrose, and glucose syrups.
2) Dextrose Purification capacity will be increased to support the additional production of fructose
and crystalline dextrose.
3) Fructose 55 (F55) production capacity will be doubled from 300 to 600 MTD.
4) Glucose syrups capacity will be increased from 125 to 155 MTD.
5) The existing (aka old) DMH line will remain the same as today, no changes.
6) In general, new processing systems such as ultrafiltration, evaporation, carbon treatment, ion
exchange, fractionation will be installed.
AXA MATRIX Risk Consultants review of this project and the resulting recommendations contained herein relate to typical property insurance purposes
only. Nothing in these project specifications should be inferred with regard to compliance with any rules, regulations or requirements of governmental
agencies, state or local codes or any jurisdictional authority. AXA MATRIX Risk Consultants assumes no liability for the proper installation or function of
the recommended systems, nor for its effectiveness to control or minimize loss. This is not a safety review and AXA MATRIX Risk Consultants
recommendations, if complied with, do not imply any duty to provide for the safety or health of any person. In addition, the recommendations herein
may not be deemed acceptable by all insuring bodies, many of which have their own standards and recommendations.
AXA MATRIX Risk Consultants

3130 South Tech Blvd., Miamisburg, OH 45342 USA
Phone: +1 937 886 0000 – Fax: +1 937 432 2099 – Internet: www.axa-matrixrc.com
a. Some new equipment will be placed in the existing refinery.
b. Some new equipment will be installed in the new refinery – note that this new refinery
will actually be integrated into the refinery process and will not serve a parallel
production line.
c. Some existing equipment will be removed or relocated to the new refinery.
7) A new MVR evaporator will be installed.
DMH2 (new line, erected in 2012)

1) Capacity will be increased from ~110 MTD to 150 MTD.
2) New Crystallizers and a centrifuge will be installed in the existing building – space for this new
equipment was foreseen in the original design.
3) New packaging line not required.
Ethanol
1) An ethanol plant with 150 m3/day capacity will be built.
2) Industrial (chemical) grade ethanol will be produced. ETBE grade (biofuel) will be produced
initially and transition to industrial grade ethanol will be over 4 years.
3) Feed streams will come from the refinery and will generally be dextrose based with minor
amounts of fructose.
a. Ultrafiltration retentate (includes concentrated protein, fats, etc. removed during the
dextrose purification process).
b. Fractionation raffinate (byproduct from the step that concentrates 42 fructose to higher
levels).
c. Dextrose greens from the DMH lines.
d. Sweet water from regeneration steps for ion exchange and carbon treatment.
e. Light steep water coming from the millhouse will provide nutrients for the fermentation
process.
4) Ethanol will be loaded in trucks, isocontainers, and railcars.
5) Location of the plant is still not finalized but could be in the northwest corner of the plant site.
CHP (Combined Heat & Power – Gas Turbine)

1) Two CHP units ~ 14 mW electricity per unit.
2) CHP turbine exhaust gases (TEG) will supply two heat recovery steam boilers (10 barg);
existing natural gas fired boilers will be placed on standby or one unit will be used if needed.
3) TEG after boilers will supply the new germ dryer, the new gluten dryer, the existing gluten dryer,
and possibly other heat recovery systems (evaporator or scrubber hot water system).
4) Natural gas pressure required for CHP will require a new line into the plant – still evaluating with
supplier if other installations are needed.
5) The CHP units and boilers will be located next to the new germ dryer, close to the new
feedhouse.
Utilities
1) Evaluating the need to install additional deep wells (specifically pumps and power, holes were
drilled in the past).
2) New sand filter and RO systems to be installed.

3) Air compressor(s) to be added for plant air.
4) Evaluating if local WWTP company can accept additional flow associated with expansion.
a. If they cannot accommodate new flow, it is needed to start-up old WWTP and segregate
streams that would go to the local WWTP and go to plant WWTP.
5) Fire Protection – need to understand requirements for ethanol facility.
General Information
1. Engineering funds for design of major equipment approved.
2. Final approval of project was originally forecasted for Q1/Q2 2017 but might be expedited to
August-December 2016.
3. General Plant simple layout in PFD is attached.
GENERAL CONDITIONS
1. Specifications for this project recommend that prints for construction, fire protection equipment,
combustion safeguards, and electrical schematics be forwarded to AXA MATRIX Risk
Consultants for review and acceptance prior to installation. Final approval of the completed
project is subject to a field review by a representative of AXA MATRIX.
2. The use of the word “approved” in these specifications means acceptable to AXA MATRIX Risk
Consultants and that equipment and materials used are listed by product name and manufacturer
in the FM Approval Guide and/or equivalent European Approval Organization.
3. The design and construction of these buildings should conform to local building codes and the
specific recommendations from AXA MATRIX.
4. Fire protection installations should be designed and installed in accordance with the guidelines
set forth by FM Global Data Sheets, National Fire Protection Association (NFPA) Standards, and
the specific recommendations of AXA MATRIX Risk Consultants.
5. Combustion safeguards and burner controls for all gas fired equipment should be installed in
accordance with FM Global and NFPA standards. All equipment components should be FM
Global Approved or Approved by an equivalent European Approval Organization.
6. In areas where explosive atmospheres may occur, prevention and protection requirements as per
ATEX directives (ATEX 100a – Directive 94/9/EC & ATEX 137 – Directive 99/92/EC) have to be
implemented. Special care should be taken in the application of these standards to electrical and
mechanical installations in hazardous areas involving corn receiving and storage, distillation, dry
feed handling and storage, and finished product ethanol storage.
7. All sprinkler piping should be installed by a “qualified” sprinkler contractor. A qualified contractor
is one that is engaged in the installation, alteration, and testing of such systems, and is familiar
with precautions required and is locally licensed to perform the work to be conducted.
8. All equipment, materials, and accessories should bear a listing/approval stamp or label.

CONSTRUCTION
1. The buildings and main infrastructures (including tank-farms) should be designed to withstand
earthquake forces in accordance with the current guidelines of FM Global Data Sheet 1-2.
According to the internationally recognized studies GSHAP & SHARE, the use of a peak ground
acceleration on rock (with a return period of 475 years) equal to 0.19g is recommended. This data
shall be corrected taking into consideration eventual amplification factors due to local soil
conditions. State and local codes should, in any case, prevail where they exceed the FM Global
guidelines (Note: According to the Bulgarian Annex to Eurocode 8 part 1 (earthquake design), the
design specification for PGA on rock is 0.15g; slightly lower than GSHAP/SHARE specifications).
2. The buildings should be designed to withstand wind forces in accordance with the current
guidelines of FM Global Data Sheet 1-28, using a basic wind speed of 40m/s (90mph) and
Ground Roughness Exposure C. Design load for both walls and roofs should be determined from
this standard using appropriate buildings heights for each area of the plant. State and local codes
should, in any case, prevail where they exceed the FM Global guidelines (Note: Razgrad is low
wind exposure – 25 to 30m/s as per Swiss Re maps (three seconds gust); maybe design could
be reduced to 35m/s. According to the Bulgaria Annex to Eurocode 1 part 4 (wind speed design),
design wind pressure is between 0.39 and 0.48 kN/m2).
3. The minimum live load design for the roof should be 1.25kN/m2 (25 psf). Where there is a
possibility that snow from a higher roof area can accumulate at the juncture of a lower roof, the
design of the lower roof should be increased to account for this possibility using FM Data Sheet
1-54.
4. Roof drainage should be designed to withstand a rainfall intensity of at least 80mm/hour (3.25
inches). If roof drains are not provided, and drainage is accomplished by water flowing off the
perimeter of the roof, a minimum roof slope of 25mm per meter (1/4 inch per foot) should be
used. If roof drains are to be provided, a minimum roof drain size of 100mm (4 inches) should be
used. The drains should not be located at the building columns, but in the center of the bay where
any sagging would normally occur. A minimum of 12mm per meter (1/8 inch per foot) of uniform
slope should be maintained toward the drains to reduce the possibility of ponded water
accumulation.
5. Any insulated metal deck roof (if provided) should be installed as a FM Global Class 1 roof
system with 1-90 wind securement and a severe hail rating (SH), using “approved” methods and
materials as shown in FM Global Data Sheet 1-29 and in the FM Global approval Guide.
Mechanical fastening should be provided in accordance with manufacturer's specifications to
secure the roof insulation to the metal deck. This should include additional fasteners in the
perimeter and corners of the roof as compared to the field area of the roof. The use of asphalt or
solvent-based adhesives is not recommended. Complete details of the proposed roofing system
should be forwarded to AXA MATRIX for review before installation.
6. Any FRP wall or roof panels used on this project should be FM Global approved as a Class I
panel to unlimited height.
7. All exposed insulating materials should be essentially noncombustible with a flame spread rating
of 25 or less. All insulation and/or insulating adhesives should be UL listed and/or FM Global
approved. All concealed spaces above suspended ceilings, etc. should be free of combustibles.

8. The following areas should be separated from adjacent areas by walls with a minimum fire rating
of two hours, and, any doors or other openings in the walls provided with an FM approved or UL
listed Class B fire door or shutter:
a. Manufacturing / storage areas from personnel and maintenance areas, if these areas are
directly adjacent each other.
b. The Main Turbine Generator Building from surrounding areas.
c. All Motor Control Centers from adjacent areas.
d. Any Computer, or Process Control/Rack Rooms from adjacent areas.
9. Any I/O racks and/or PLCs should not be exposed to MCC equipment. If located in an MCC
Room, the I/O racks and /or PLCs should be separated by a 2-hour wall with Class B doors in any
openings between the two areas.
10. Any penetrations of fire rated walls by pipe or cable trays or other utilities should be sealed to full
wall thickness with masonry grout or be fire-stopped with an FM approved fire-stop material.
Combustible foam products should not be used for sealing any openings in fire rated walls around
cable tray, pipe, etc.
11. The Distillation Building should be located a minimum of 30m (100 ft.) from any other structures
or critical facilities. This building should be designed as damage limiting, with explosion relief at a
minimum of 0.1m2 of venting for each 0.4m3 of building volume (1 ft. squared of venting for each
15 ft. cubed of building volume). Pressure resistant (damage limiting) and fire rated (minimum two
hours) wall construction should be provided between each modular distillation “cell.”
12. Each “cell” housing one of the modular distillation processes should have a designed emergency
drainage system (beyond that required specifically for general drainage and spill control) for all
solid floor levels and for the ground floor. The system should be designed to handle the maximum
expected fire protection system flow requirements. The drainage system should terminate at a
remote impounding or containment basin. This containment basin should be located as far as
possible from the building (at least 7.6m (25 ft.)).
13. The ethanol tank farm should consider the following:
a. The tank farm should be located a minimum of 30m (100 feet) from any building.
b. All tanks in the tank farm should be floating roof type with a metallic pontoon style floating
roof.
c. Individual diking should be provided for aggregate volumes exceeding 20,000m3

(5,000,000 gallons).
d. Tank to tank spacing should be a minimum of ½ the diameter of the largest tank.
e. Tank to dike wall spacing should be a minimum of ½ the diameter of the tank.

f. When calculating the dike capacity, it should be able to contain the largest tank volume
(in that dike section) and the volume of all surrounding tanks. (Volume below the top of
the dike in that dike section should be deducted when calculating this dike capacity.)
g. It is not recommended that any drainage systems from ethanol loading, or raw material
unloading areas be piped to any dike area for the tank farm.
h. Separate containment capacity should be designed for the rail and truck loading, and
denaturant unloading areas. It is recommended that this containment be individualized for
each loading position.
14. The Elevator, Corn Receiving and Corn Screening areas should consider the following:
a. Any enclosed building areas, work house, screening areas, conveyor galleries (if
provided) should be designed as damage limiting in accordance with FM Global Standard
No. 1-44.
15. To help control the oil hazard associated with the turbine generators, the following should be
considered in the design:
a. All lube and control oil tanks should be installed in a curbed area with sufficient capacity
to hold the contents of the tanks. Any oil filtering, purifying and centrifuging equipment
should be located in a curbed area. If there are to be any below grade pits, these should
be curbed to minimize the chance of any oil spills accumulating in these areas.
b. The floor area between adjacent turbine generators should be curbed or sloped to
prevent oil spills or leaks from flowing beneath the adjacent unit. A combination of curbs,
ramps and drainage to a properly designed oil separator to minimize exposure under fire
conditions should be provided.
c. Where possible, separate oil and steam lines from each other by physical separation or
noncombustible barriers. As a minimum, locate oil line beneath steam lines. Insulation for
steam lines should be metal covered or should be of a type that will not absorb oil.
d. The routing of cables supplying the AC and DC lube oil pumps should be physically
separated to minimize the loss of both supplies from a single exposure.
16. The construction of a new Fire Pump House should be detached from any main plant buildings by
at least 25m (75 ft.) and should be of noncombustible construction. The pump room roof should
be reinforced concrete. The Pump Room floor should be provided with a drain to accommodate
any required relief valves or pump cooling water discharge requirements.

WATER SUPPLIES
1. The design of the water supply should be based on the maximum expected total sprinkler system
demand at the Distillation Facility. With proper fire-rated and blast resistant construction between
“cells” this can be based on the operation of one “cell’s” fire protection system. The tank size
should be based on this maximum sprinkler demand over a 2-hour duration. The number of fire
pumps required would be based on that needed to meet the maximum demand plus one
additional fire pump for redundancy. At a minimum, two “approved” 795m3/h @ 9bar (3,500gpm
at 130psi) rated automatic starting diesel or electric motor driven fire pump should be provided.
The fire pumps should take suction from a minimum 3,800m3 (1,000,000 gallon) steel suction
tank. The water in the tank should be heated to maintain a temperature of 4°C or above.
2. The pumps should be installed per NFPA Standard No. 20 and should be arranged to start on a
pressure drop. Diesel engine cooling water, pump bearing cooling water and pump casing relief
valves, etc. should be designed to discharge to a floor drain or directly to the exterior of the
building. They should not be piped to the suction tank.
3. A small jockey pump rated at approximately 10m3/h @ 10.5bar (50 gpm at 150 psi) should be
provided to maintain pressure on the underground fire main.
4. The electric supply for any electric fire pump should be taken ahead of all plant disconnects and
should be installed in strict accordance with NFPA Standard No. 20 requirements.
5. The steel suction tank should be able to be filled from a public or private water supply, at a rate
adequate to provide sufficient water storage within eight hours. The fill line should be
automatically operated.
UNDERGROUND FIRE MAINS, SECTIONAL VALVES AND HYDRANTS
1. Minimum 400mm (16-inch) private underground fire main should be provided to loop this entire
facility. Appropriate sectional and riser control valves should be provided. PIV style valves should
be given preference over underground or roadway type valves for accessibility purposes where
possible. If roadway style valves must be installed, they should be designed to assure the top of
the valve is located approximately one inch above the surrounding grade level, and should be
surrounded by a sloped concrete or asphalt pad flush with the top of the valve. An appropriate
length Tee handle wrench should be provided and mounted adjacent any grouping of roadway
style valves. All valves should be FM approved right hand valves, designed to open in the
counterclockwise direction.
2. AXA MATRIX would like to review the proposed underground layout to include the overall layout
of pipe, hydrants and lead-ins to sprinkler risers. We recommend that no sprinkler lead-in supply
more than three sprinkler systems.
3. The underground fire main piping and fittings should be FM Global approved for fire main
purposes. Cement-lined ductile iron pipe is preferred. Work and installation procedures should be
in accordance with NFPA Standard No. 24.
4. Thrust blocks and rodding should be provided for the underground piping at all changes in piping
direction.

5. The underground fire main piping should be tested hydrostatically at no less than 15.5bar (225
psi) for two hours. This testing should be witnessed by a representative of ADM.
6. Copies of the properly completed Contractor's Material and Test Certificate (CMTC) should be
forwarded to AXA MATRIX.
7. Standard two-way, frost proof fire hydrants should be provided on the underground fire main at
intervals not to exceed 90m (300 ft.), except in areas of minimal hazard, where 150m (500 ft.) can
be considered maximum spacing. Each hydrant should be equipped with a roadway valve to
isolate the hydrant from the underground main, as well as individual shutoff valves on each
hydrant butt. Threads should match that of the local responding public fire department.
AUTOMATIC SPRINKLER PROTECTION
1. Automatic sprinkler protection in accordance with FM Global Data Sheet 7-14 should be provided
for the Distillation Building. Each cell should be individually designed as a separate protected
area. Automatic deluge sprinkler protection should be provided throughout each “cell.” All
protected Cell system(s) should be designed to provide a 12.2mm/min (0.30 gpm/sq. ft.) density
at the ceiling of the building, over any solid floor levels, and over the ground level (first floor)
simultaneously with a 6.1mm/min (0.15 gpm/sq. ft.) density under any open grated metal floor
levels. This system can be activated by pilot line sprinkler QR type, C-1 thermostatic release, or
linear heat detection wire. More Specific design criteria should be obtained when plans are more
formalized. As an example the height of the floor levels can affect the need for additional column
or lower level sprinkler protection. Total demand calculations would be dependent on the
operation of one cell’s fire protection system as long as the construction features meet point 10 in
the Construction section.
2. Depending on the actual design of the floating roof, in tank automatic foam protection should be
provided for the seal area or for the entire surface area in accordance with NFPA 11. The actual
design basis for the in tank protection will depend on the floating roof type. Floating roof tanks
with an acceptable floating roof type can be protected with a seal area system designed for a
12.2mm/min (0.30 gpm/sq. ft.) density over the seal area for 20 minutes. Foam dams should be a
minimum of 300mm (12 inches) high. For 300mm (12-inch) foam dams the maximum spacing
between nozzles should be 12.2m (40 ft.), for 600mm (24-inch) foam dams the maximum spacing
between nozzles should be 24.4m (80 ft.) For fixed roof tanks, and unacceptable floating roof
type tanks, the design of the system should be a minimum of 4.1mm/min (0.10 gpm/sq. ft.) over
the entire surface area of the tank for 55 minutes (type 2 outlet). The actual density will depend
on the specific foam chosen and based on the manufacturer’s recommendations. The tank farm
diked area should be protected by an against the dike wall foam system designed for a minimum
discharge rate of 4.1mm/min (0.10 gpm/sq. ft.) over the entire dike wall area or the entire dike
wall area of any of the separate subdivisions. Design should be in accordance with NFPA
Standard No. 11. Foam water spray protection is also recommended for each individual
containment area for the loading of Ethanol, or unloading of denaturant. This protection should be
provided at the rates identified by the UL listings for the specific foam concentrate and sprinkler
head combination chosen.
3. Automatic wet pipe or dry pipe sprinkler protection should be provided in the New Feed House,
including adjacent Germ Dryer, Fiber Dryer, and any enclosed area, using a hydraulically
designed sprinkler system calculated to provide a density of 10.2mm/min over the most remote
280m2 area (360m2 for dry systems) (0.25 gpm/sq. ft. over the most remote 3,000 sq. ft. (3,900

sq. ft. for dry systems) area), including a 1900l/min (500gpm) allowance for hose streams.
Sprinklers should be rated at 141°C (286°F), and a maximum spacing of 9.3m2 (100 sq. ft.) per
sprinkler head should be used. For wet pipe systems all pipe should be Schedule 40 black steel.
For dry pipe systems all pipe should Schedule 40 galvanized.
4. Automatic wet pipe or dry pipe sprinkler protection should be provided in the New Gluten Dryer,
including any adjacent enclosed area, using a hydraulically designed sprinkler system calculated
to provide a density of 10.2mm/min over the most remote 280m2 area (360m2 for dry systems)
(0.25 gpm/sq. ft. over the most remote 3,000 sq. ft. (3,900 sq. ft. for dry systems) area), including
a 1900l/min (500gpm) allowance for hose streams. Sprinklers should be rated at 141°C (286°F),
and a maximum spacing of 9.3m2 (100 sq. ft.) per sprinkler head should be used. For wet pipe
systems all pipe should be Schedule 40 black steel. For dry pipe systems all pipe should
Schedule 40 galvanized.
5. Automatic wet pipe or dry pipe sprinkler protection should be provided in the Corn Receiving
Building, and any enclosed Corn Handling area using a hydraulically designed sprinkler system
calculated to provide a density of 10.2mm/min over the most remote 280m2 area (360m2 for dry
systems) (0.25 gpm/sq. ft. over the most remote 3,000 sq. ft. (3,900 sq. ft. for dry systems) area),
including a 1900l/min (500gpm) allowance for hose streams. Sprinklers should be rated at 141°C
(286°F), and a maximum spacing of 9.3m2 (100 sq. ft.) per sprinkler head should be used. For
wet pipe systems all pipe should be Schedule 40 black steel. For dry pipe systems all pipe should
Schedule 40 galvanized.
6. Automatic sprinkler protection should be considered for any Electrical Equipment Room, if heavy
combustible loading is present from grouped electrical cables or from anticipated combustible
storage. Special consideration should be given to cable spreading room below main electrical
substation. Protection should be provided using a hydraulically designed sprinkler system
calculated to provide a density of 8.1mm/min (0.20 gpm/sq. ft.) over the entire area or most
remote 280m2 (3,000 sq. ft.) area, including a 1900l/min (500 gpm) allowance for hose streams.
Sprinklers should be rated at 74°C (165F) and a maximum spacing of 12m2 (130 sq. ft.) per
sprinkler head should be used.
7. Because of combustible construction, automatic wet pipe or dry pipe sprinkler protection should
be provided in the existing Mill House and Refinery, using a hydraulically designed sprinkler
system calculated to provide a density of 7.5mm/min over the most remote 230m2 area (300m2
for dry systems) (0.18 gpm/sq. ft. over the most remote 2,500 sq. ft. (3,300 sq. ft. for dry systems)
area), including a 950l/min (250gpm) allowance for hose streams. Sprinklers should be rated at
68°C (160°F), and a maximum spacing of 12.1m2 (130 sq. ft.) per sprinkler head should be used.
For wet pipe systems all pipe should be Schedule 40 black steel. For dry pipe systems all pipe
should Schedule 40 galvanized.
8. Most likely, automatic sprinkler protection will not be required in the New Refinery Building (F-55
Fructose). But this needs to be confirmed based on any possible large hydraulic or large
lubrication systems that might be provided in the building.
9. Automatic deluge sprinkler protection should be provided for cooling towers provided for this
project as well for existing ones. The sprinkler density should be provided per NFPA Standard
No. 214 based on the type and design of the tower. The fans should be arranged to shut down
upon sprinkler waterflow. AXA MATRIX also recommends that four way bracing be provided at

the top of the each sprinkler riser, combined with a mechanical groove coupling located within
600mm (24 inches) of the top of the riser. Actuation of the deluge system may be via a system of
linear detection or fixed spot detectors, pilot line sprinklers, etc. If FM Global approved cooling
towers are provided and installed in accordance with their approval guidelines, then automatic
sprinkler protection will not be required. Piping should be schedule 40 galvanize or stainless steel
if desired.
10. Provide sprinkler systems piping protection against damages from earthquakes.
11. Most sprinkler systems should be calculated based on 150% of the rated flow at 65% of the rated
pressure for one fire pump.
12. The total demand in the Distillation facility should be calculated based on 150% of the rated flow
at 65% of the rated pressure of the least number of fire pumps required.
13. All calculations should be balanced back to the water supply source and should be designed to
maintain a minimum 0.5bar (5 psi) cushion, including hose demand.
14. In designing the sprinkler hydraulic area, the dimension of the design area parallel to the branch
lines should be equal to 1.4 times the square root of the design area.
15. Each lead-in supplying a sprinkler system should be controlled by a post indicator valve located
approximately 8-12m (25-40 ft.) from the building. Valves shall open in the counterclockwise
direction.
16. The new sprinkler systems should be tested hydrostatically at not less than 15.5bar (225 psi) for
two hours. This testing should be witnessed by a representative of ADM.
17. Copies of the properly completed Contractor's Material and Test Certificate for each sprinkler
system should be forwarded to AXA MATRIX.
18. Galvanized piping (including the inside of the pipe) should be used in any new dry-pipe, deluge or
pre-action systems where ambient temperature does not exceed 54°C (130°F). Fittings need not
be galvanized. Any exposed threads or wrench marks should be coated with cold galvanize or
other corrosion resistant coating to prevent premature failure where the factory galvanize coating
has been disturbed. When the ambient temperature exceeds 54°C (130°F), black steel pipe
should be used. At ambient temperatures above 54°C (130°F) the corrosion of zinc is greatly
accelerated and peaks at about 66°C (150°F). Black steel pipe provides better corrosion
resistance at high ambient temperatures. With galvanized piping, a Hazen-William's “C” value of
120 may be used in system calculations.
19. Any dry pipe, pre-action and deluge sprinkler systems should be provided with an air dryer for:
a. The air supply to the sprinkler piping.
b. The air supply to the heat detection system when pneumatic tubing is used for heat
detection in pre-action and deluge sprinkler systems.

20. Any dry pipe, pre-action and deluge system should be trip tested per NFPA Standards and
documented on the Contractor’s Materials and Test Certificate. For any dry pipe systems, water
must reach the inspector's test connections within 60 seconds of opening the inspector's test
valve, starting at normal air and water pressure. If water does not reach the inspector's test
connection of a system within 60 seconds, an accelerator and/or exhauster should be installed on
the system. Any foam water systems should be acceptance tested per NFPA 16.
21. A supply of spare sprinkler heads should be provided and installed at each riser per NFPA
standards. If desired and agreed to by the plant, spare heads may be labeled and provided
directly to the plant maintenance department for central storage rather than field storage in
cabinets at the risers.
22. All sprinkler risers should be installed in a dedicated riser room, complete with adequate room to
perform normal system maintenance. Adequate heat and lights should be provided in each Riser
Room.
23. All dry pipe, deluge or other system requiring an air supply should be provided with an approved
air maintenance device and two means of air supply, which may include plant air, as well as a
back-up air compressor located in the sprinkler riser room.
24. Complete manufacturers' maintenance and instruction manuals should be left at the plant. Plant
Maintenance employees should be trained in tripping and resetting procedures for all dry pipe,
pre-action and deluge valves and any foam-water systems.
PROCESS CONTROL and I/O COMPUTER ROOM PROTECTION
1. Where possible, significant concentrations of Process Control and I/O equipment should be
located separate from higher voltage electrical equipment areas by the provision of walls with a
minimum 1½ hour fire rating. Automatic closing, Class B fire doors should be provided at all
openings. Wall penetrations should be sealed with approved fire stop material and installation
practices to meet the 1½ hour fire rating.
2. For rooms containing critical electronics and instrumentation systems and significant
concentrations of I/O racks and PLCs, consideration should be given to installation of an
approved total room flooding, or in-cabinet gaseous suppression system, to minimize downtime
and business interruption losses. Design of these systems should incorporate the latest
technology including activation by HSSD (High Sensitivity Smoke Detection) systems. Where
raised floors with significant below floor grouped cables are involved, detection and suppression
should be extended to those areas as well. The design of all systems should be in accordance
with NFPA 2001. A final acceptance test including room integrity testing to assure the gas can be
properly contained for the 10 minute design demand period should be planned for all systems.
Care should be taken during the design of the room to include provision for isolation and/or
shutdown of the HVAC system. Each area, once defined, should be discussed with AXA MATRIX
to determine the best and most cost effective way to minimize the hazard.
3. The routing of control and instrument wiring should consider minimizing the exposure from lube or
hydraulic oil fires or other fire type exposures. Where cable trays are exposed to lubrication or
hydraulic oil fires, the cable trays should be wrapped with 1 hour fire rated material.

4. Provide separate routing for the control wiring and power cable for both the primary and
secondary lube oil pumps. In addition, DC and AC pump wiring should be separated and routed
independently.
SPECIAL PROTECTION
1. Gas Turbine and Generator Enclosures – Fixed automatic extinguishing systems should be
provided in accordance with FM Global Loss Prevention Data Sheet 7-79, Fire Protection for Gas
Turbines and Electric Generators, for:
a. The inside of the turbine compartments as well as the enclosures for auxiliary equipment.
b. All turbine building areas subject to oil fires that expose important equipment.
The current proposal is to provide a carbon dioxide (CO2) delivery system for the enclosures.
Alternatives available are inert gas, total flooding water mist systems, and hybrid systems
combining water and inert gas.
Design the extinguishing system to maintain the required agent concentration or provide a
discharge duration, as applicable, equal to the greater of:
- 20 minutes.
- The maximum projected time needed to achieve a safe shutdown of the lube-oil system
following emergency trip of the turbine, plus 10 minutes.
- The maximum projected time to allow exposed hot surfaces to cool below the auto-
ignition temperature of the oil.
The following guidelines should be used depending on which option is selected for protecting
these enclosures.
The various options include:
- An FM Approved inert gas or carbon dioxide total flooding system. A fire extinguishing
system that relies on filling an enclosure with an extinguishing agent, and maintaining
the extinguishing concentration within the enclosure until the fire is extinguished and
conditions will not permit re-ignition.
o Provide sufficient agent to achieve an initial CO2 design concentration of at

least 34% by volume within one minute, and maintain a minimum of 30% for the
remainder of the concentration hold time determined above.
o Locate and orient CO2 discharge nozzles to avoid direct impingement by the
discharge jet onto the gas turbine.
o For other inert gas systems, provide sufficient agent to achieve and maintain a
concentration in accordance with the manufacturer’s recommendations and
applicable NFPA and FM Global Data Sheet 4-9, Clean Agent Fire
Extinguishing Systems, for the concentration hold time determined above.
Locate and orient discharge nozzles to avoid direct impingement by the
discharge jet onto the gas turbine.
- Total flooding water mist system (FM Approved for the protection of gas turbine or
machinery in enclosures, as applicable). This is a special protection system in which a

distribution system is connected to a water supply that is capable of delivering atomized
water spray with droplets that are less than 1,000 microns in size. The smaller droplets
vaporize and extract heat more rapidly from flames and are able to extinguish spray
fires.
- Hybrid (water and inert gas) system (FM Approved for the protection of gas turbine or
machinery in enclosures, as applicable). Both the water and the inert gas are critical
factors in fire extinguishment, for the purposes of cooling and inerting.
o For both water mist or hybrid (water and inert gas) systems, install the system
in accordance with its listing in the FM Approval Guide, the manufacturer’s
recommendations, NFPA standards, and Data Sheets 4-0, Special Protection
Systems, and 4-2, Water Mist Systems, as applicable.
o Ensure all system limitations, such as protected volume size, ventilation rate,
and opening size, are met.
o Hydraulically design the water mist or hybrid system in accordance with the
manufacturer’s recommendations and the system’s listing in the FM Approval
Guide.
o Design the water mist or hybrid agent supply to provide discharge to the largest
single hazard zone or group of hazard zones protected by the system
simultaneously, for the time specified above.
o Locate and orient discharge nozzles in accordance with the manufacturer’s
instruction.
- Where fuel, lubrication, and hydraulic oil tanks, pumps, or other equipment not subject
to potential water damage are inside a dedicated room or an enclosure, automatic
sprinkler protection designed in accordance with applicable standards may be provided
as an alternative to options A, B or C.
DO NOT PROVIDE THIS OPTION FOR GAS TURBINE ENCLOSURES.
2. Switchgear and MCC Rooms – All electrical rooms should be provided with an approved system
of smoke detection, arranged to alarm at a central alarm location and system. Each room should
be zoned to annunciate individually. Other systems such as HSSD systems, beam smoke
detection, etc. may be used in rooms having high BI exposure or requiring an excessive amount
of spot smoke detection, based on the physical layout.
3. Cable Trays – In Electrical Rooms or other areas in the plant, special precautions are needed
when cable trays are stacked more than two trays high or are stacked less than 18 inches apart
vertically. Should the project have areas with cable trays stacked greater than two high, please
contact AXA MATRIX to discuss the various options which may include spacing requirements,
use of approved, Group 1 cable, spray fire proofing, additional sprinklers, etc. The routing of cable
trays and wiring should consider minimizing the exposure from lube or hydraulic oil fires or other
fire type exposures. Where cable trays are exposed to lubrication or hydraulic oil fires, the cable
trays should be wrapped with 1 hour fire rated material.
4. Transformers – The transformer yard offers a substantial exposure to this facility. The separation
distance between the transformers and the building, as well as the separation of each transformer
from the adjacent unit should be addressed via space separation, the use of fire rated walls, and

for all cases, a containment and drainage system. Separation distances are driven by the gallons
of mineral oil in each unit. The following are based on NFPA and FM requirements:
For units with oil capacity < 18,900l (5,000 gallons) mineral oil:
A. Separation distance between edge of diked areas and adjacent buildings – 7.6m (25 ft.)
B. Separation distance between transformer diked areas - 7.6m (25 ft.)
C. Separation walls required between transformers - NO*
D. Deluge system exposure protection for buildings walls required - NO
For units with oil capacity> 18,900l (5,000 gallons) mineral oil:
A. Separation distance between edge of diked areas and adjacent Buildings - 15m (50 ft.)
B. Separation distance between transformer diked areas – 15m (50 ft.)
C. Separation walls required between transformers - NO*
D. Deluge system exposure protection for buildings walls required? - NO
*The separation distance between transformers can be reduced as needed if a minimum 2-hour
rated fire barrier wall is provided between units. Walls should extend 0.3m (1 ft.) vertically and
0.6m (2 ft.) horizontally beyond transformer components that could be placed under pressure as a
result of an electrical fault. The wall should be designed to withstand all expected wind loads.
Transformer Containment – All transformers should be provided with a pit or diked area with a
drainage system designed to remove rainwater. Containment should be separate for each
transformer.
5. Natural Gas Compressor Skid – The natural gas equipment skid should be located at least 15m
(50 ft.) from any important plant equipment or buildings. Plant operators should have the ability to
isolate the natural gas equipment skid remotely from the Control Room, as well as manually from
valving located at a safe distance from the natural gas skid. The natural gas skid area should be
provided with a leak detection system which can reliably and promptly identify leaks and initiate
shutdown of the turbine and fuel supply prior to ignition of a fire or a flammable cloud capable of
deflagration (vapor cloud explosion). The system should be robust and reliable but also be
designed to avoid spurious trips due to detector malfunctions, software errors, and operation
upsets of a non-emergency nature. Seismic shut-off valve, automatically activated in case of an
earthquake, should be provided to cut-off gas supply in case of an earthquake.
6. Lubrication, Control, and Seal-Oil Piping – The piping should be designed and installed to
minimize the chances of a break in the pipe or fittings in the event of turbine vibration as outlined
in Section 2.2.7 of the FM Global Data Sheet 7-79.
7. Distillation and Ethanol Bulk Storage Areas – The following should be considered:
a. Equipment (machines, electrical apparatus, fixed or mobile devices, control components

and instrumentation, detection or prevention systems, etc.) in areas potentially exposed
to gas or vapour explosions should feature explosion-proof characteristics. According to
ATEX Directive 94/9/EC, equipment should feature the following requirements:
i. Group II, Category 1 G in areas where explosive atmospheres are present
continuously, for long periods or frequently (Zone 0).
ii. Group II, Category 2 G in areas in which explosive atmospheres are likely to
occur occasionally (Zone 1).

iii. Group II, Category 3 G in areas in which explosive atmospheres are unlikely to
occur or, if they do occur, are likely to do so only infrequently and for a short
period only (Zone 2).
Risk Assessment shall be conducted on the base of ATEX Directive 99/92/EC, in order to
classify the areas (0, 1 or 2, according the likelihood of having an explosive atmosphere)
and determine the extent of relevant classified areas.
b. Provide well designed low level mechanical ventilation across all solid floor levels in the
Distillation Building. The ventilation system should be designed to change the volume of
air in the building 6 times per hour. Make-up air vents and extraction air vents should be
designed and located to create a sweep across the entire floor. A flammable vapor
detection system should also be provided for the building.
c. Bulk storage tanks for the storage of Ethanol, Denaturant and Rust Inhibitor should be
fitted with fusible link operated safety shut off valves on any discharge lines below liquid
level. The new tanks should be provided with conservation and emergency venting. The
emergency venting should be designed for fire exposure to the tanks. Pumping systems
for the tanks should be located in the diked area. Operation of the pumps and
recommended binary valving slave to pump operation should be interlocked with an e-
stop process interlock and/or sprinkler system operation in the Processing Building
and/or tank farm. The bulk solvent unloading zone should be located at least 30m (100
ft.) from the Processing Building and 7.6m (25 feet) from any other building.
d. In the Distillation Building it is recommended that all process equipment emergency vents
be separately vented to outdoors. If vent lines at each processing tank, vent condenser,
and still are all manifolded together then they should be fitted individually with detonation
arresters. It is assumed these vent lines would be sized for conservation venting
purposes. If so, then additional emergency vents should be provided for each tank and
the still designed for fire exposure to the equipment or process upset conditions
whichever is greater.
e. Electrically bond all process equipment, building structure, vessels, tanks etc. Ground the
building structure.
8. Corn Receiving and Dry Feed Processing Areas – The following features should be
considered as needed, based on the processing conditions and whether or not the processes are
enclosed etc:
a. Equipment (machines, electrical apparatus, fixed or mobile devices, control components

and instrumentation, detection or prevention systems, etc.) in areas potentially exposed
to dust explosions should feature explosion-proof characteristics. According to ATEX
Directive 94/9/EC, equipment should feature the following requirements:
i. Group II, Category 1 D in areas where explosive atmospheres are present
continuously, for long periods or frequently (Zone 20)
ii. Group II, Category 2 D in areas in which explosive atmospheres are likely to
occur occasionally (Zone 21)
iii. Group II, Category 3 D in areas in which explosive atmospheres are unlikely to
occur or, if they do occur, are likely to do so only infrequently and for a short
period only (Zone 22)

Risk Assessment shall be conducted on the base of ATEX Directive 99/92/EC, in order to
classify the areas (20, 21 or 22, according the likelihood of having an explosive
atmosphere) and determine the extent of relevant classified areas.
b. Appropriately designed local ventilation to control dusty conditions from processing

equipment.
c. Rotary air lock valving for all bottom discharge equipment where possible.
d. Explosion venting to outside or explosion suppression system protection for all storage
hoppers/bins. For the explosion venting option, explosion isolation (chemical isolation)
should be considered on the inlet duct to the equipment and the outlet duct from the
equipment if no rotary air lock valve is provided. All storage silos and/or bin vents should
be individually vented, manifolding of silo or bin vents is not recommended.
e. All bucket elevators should be fitted with explosion venting design. XPAC 3 explosion
system protection (with chemical isolation on inlet/outlet chutes) should be provided for
any bucket elevators. Appropriate bucket elevator monitoring should include a watchdog
system monitoring belt alignment, bearing temperature and 20% belt slow down.
f. Where possible and practical bucket elevators should be located outdoors. Bucket
elevators located outdoors should also have explosion venting design (relief panels).
g. Electrically bond all process equipment, building structure, vessels, tanks etc. Ground the
building structure.
h. Any enclosed belt conveyors should be provided with belt alignment interlocks, and 20%
belt slow down switches.
9. Dust Collectors / receivers – The following items are recommended for all dust
collectors/receivers handling combustible dust to include units associated with corn handling and
receiving, dry feed processing and storage:
a. All dust collectors should be located outdoors.
b. All dust collectors should have designed emergency venting for the particular dust
explosion hazard.
c. Explosion isolation protection should be provided for all appropriate incoming and
outgoing duct work not isolated by air locks.
d. Automatic sprinkler protection should be provided in all dust collectors.

FIRST AID PROTECTION
1. Approved, multipurpose dry chemical extinguishers with a minimum 9kg (20 lb.) capacity should
be provided based on one unit per 280m2 (3,000 sq. ft.) of floor area.
2. Inside, 40mm (1½ inch) fire hose stations equipped with 25m (75 ft.) of single jacket, lined hose
and an adjustable spray nozzle should be provided for the following areas:

a. To cover all areas of any buildings not provided with sprinkler protection, and the outdoor
areas associated with the Feed Drying area.
b. To cover all areas associated with corn milling and outdoor areas at Corn Receiving.
c. To cover all Warehouse areas.
The hose should be provided on wet pipe or pre-action type systems as required by heat
availability in the area.
This hose should have a minimum “service test pressure” of 14bar (200 psi) and be listed for
Class II (NFPA) standpipe services.
3. Outside, an adequate number of fully equipped hose houses should be provided. Each hose
house should be equipped with at least 75m (250 ft.) of approved 65mm (2½ inch) lined fire hose
and 45m (150 ft.) of approved 40mm (1½ inch) lined fire hose. All fire hose should have a
minimum “service test pressure” of 14bar (200 psi). One 60mm x 40mm x 40mm (2½ inch x 1½
inch x 1½ inch) gated wye, two 40mm (1½ inch) adjustable spray nozzles, four spanner
wrenches, two hydrant wrenches, and two hose coupling gaskets should be provided for each
house.
ALARMS/WATCHMEN
1. A UL listed and /or FM approved alarm monitoring system should be provided to supervise all
alarms associated with any fire protection systems installed as a part of this project. The alarm
system should be installed in accordance with NFPA 72 and appropriate subsections; and should
include a minimum 24 hour battery back-up electrical supply. The alarm system should monitor
as a minimum the following items:
a. Sprinkler system waterflow and all low air supervisory systems for dry pipe, deluge or
pre-action systems.
b. Heat, smoke or linear detection systems wherever provided.
c. Any special hazard protection systems such as FM200, Inergen, CO2.
d. Diesel fire pump running, loss of AC power, pump trouble, switch to any position other
than automatic, low fuel level.
e. Electric fire pump running (if provided), loss of power and phase reversal.
f. Fire pump suction tank low water level and low water temperature.
It will be acceptable to provide an installation of local, strategically placed alarm panels which can
be networked to the security center at the Corn Processing Plant. Provision should be made to
assure that all alarms can also be monitored in the Main Control Room.

LOSS PREVENTION DURING CONSTRUCTION
1. Combustibles should be kept to a minimum inside the confines of the building during construction.
All contractors' sheds should be located outside the building at least 15m (50 ft.) away.
2. All necessary cutting and welding should be strictly supervised during the final stages of
construction.
3. Hydrant protection should be available as soon as possible, and emergency protection in the form
of portable fire extinguishers should be provided once the building is enclosed.
4. Adequate precautions should be taken to prevent damage by wind forces during construction.
Untied structural steel work and/or partially completed walls should be provided with temporary
bracing before discontinuing construction operations overnight or on weekends.
5. Approved watchman service should be provided when the building is enclosed and can be
discontinued if, and when, approved central station or remote station alarm supervisory service is
provided.
6. Temporary wiring should be removed upon completion of the job for which it was intended.
7. The building should not be occupied or used for any type of storage until automatic sprinkler
protection is in service and the recommended watchman and/or alarm supervisory service has
been provided.
8. Only “approved” temporary heating equipment (if needed) should be used. There should be no
open fires or salamanders in the vicinity of the construction project.

MACHINERY and EQUIPMENT RISK CONSIDERATIONS, RECOMMENDATIONS, and ADVICE
No detailed specifications provided at this stage, since information provided about machineries /
equipment is limited; hereunder follow general specifications and/or reference Loss Prevention standards
for most important section of expansion project.
1. Provide on-line monitoring for vibration, temperature (oil and bearings) and pressure (oil) on all
rotating equipment considered important to plant operations.
2. Provide that gas turbines and associated generators are protected respectively as per FM Global
Datasheets 13-17 Gas Turbines and 5-12 Electric AC Generators.
3. Provide that Heat Recovery Boilers are protected as per FM Global Datasheet 12-14 Waste Heat
Boilers.
4. A stack bypass system, which allows the gas turbine-generator to continue to generate electricity
if the HRSG is down for any reason (safety trip, inadvertent trip, HRSG failure, etc.), should be
provided. While it is likely not an economic advantage to operate the GT in simple cycle mode,
there may be production benefits to be able to operate in simple cycle mode during emergencies
or other upset conditions, while maintaining steady electric generation levels. Otherwise a HRSG
trip will trip the gas turbine generator. Note that some HRSGs can operate without water flow, in
essentially a bypass mode, but without the need for a bypass stack and stack damper, but repairs
cannot be made to this type of HRSG while generating.
5. Include infrared inspection windows on switchgear while maintaining all ratings and safety
parameters of the gear. Consideration should be given for remote manual operation of key circuit
breakers.
6. Ensure a complete set of spare parts is available for all machineries / equipment considered
important to plant operations; alternatively, develop Business Continuity Plans in order to ensure
minimization of downtime.
7. Operator training should include theory of operations as well as use of a simulator and how to
interpret all readings, alarms, etc. Maintenance staff training should include control system
testing, maintenance, and trouble shooting. Operators and maintenance technicians should work
with the commissioning team as part of their training.


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General Specifications Report /

Date: 28 JUL 2016

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DMH2 (new line, erected in 2012)

CHP (Combined Heat & Power – Gas Turbine)

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b. The Main Turbine Generator Building from surrounding areas.

c. All Motor Control Centers from adjacent areas.

d. Any Computer, or Process Control/Rack Rooms from adjacent areas.

13. The ethanol tank farm should consider the following:

c. Individual diking should be provided for aggregate volumes exceeding 20,000m3

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a. The air supply to the sprinkler piping.

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The various options include:

o Provide sufficient agent to achieve an initial CO2 design concentration of at

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a. Equipment (machines, electrical apparatus, fixed or mobile devices, control components

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a. Equipment (machines, electrical apparatus, fixed or mobile devices, control components

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b. Appropriately designed local ventilation to control dusty conditions from processing

a. All dust collectors should be located outdoors.

d. Automatic sprinkler protection should be provided in all dust collectors.

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c. To cover all Warehouse areas.

b. Heat, smoke or linear detection systems wherever provided.

c. Any special hazard protection systems such as FM200, Inergen, CO2.

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