C116-10EMD-001 - Rev C - BASIS OF DESIGN

PT MULTI NITROT AM A KIMIA
PREPARED CP Doc. No. C116-10EMD-001

CHECKED SK Contract No. C116
BASIS OF DESIGN
APPROVED YM Sheet No. 1 of 122
DATE 14.08.09 Rev. No. C
PROJECT: MNK – 2 PROJECT SITE: CIKAMPEK, INDONESIA
BASIS OF DESIGN
FOR
NITRIC ACID RELOCATION PROJECT
LOW DENSITY AMMONIUM NITRATE PLANT,
EMULSION PLANT, OFF SITES AND UTILITIES
PROJECT DATA, SITE DATA, UTILITY DATA,

PRODUCT DATA,
AND UNITS
C Update Changes CP SK YM 14.08.09

B Re-issue for use CP SK YM 17.07.09
A Up date CP SK YM 07.07.09
2 Issued for Use CP SK YM 25.06.09
1 Issued for Review CP SK YM 22.05.09
0 Preliminary Issue CP SK YM 12.05.09
REV DESCRIPTION PREPARED CHECKED APPROVED DATE
This document has been prepared by PT MNK, INDONESIA. This document is exclusive property of MNK. Unauthorized communication or reproductions not permitted.
BASIS OF DESIGN
TABLE OF CONTENTS
1 GENERAL PLANT SITE AND LOCAL CONDITION ……………………………………… 10

1.1 Introduction to Proposed Plant Site ………………………………………………..... 10
1.2 Site Data Local Condition …………………………………………………………..... 10
1.3 Climatic Data .………………………………………………………………………….. 10
1.3.1 Rainfall Data …………………………………………………………………. 10
1.3.2 Barometric Pressure ………………………………………………………… 11
1.3.3 Wind Rose …………………………………………………………………… 11
1.3.4 Ambient Temperature ………………………………………………………. 11
1.4 Design Data ……………………………………………………………………………. 12
1.4.1 Design Rainfall Data ………………………………………………………… 12
1.4.2 Design Wind Data …………………………………………………………… 12
1.4.3 Design Air Temperature – Cooling Tower ………………………………... 12
1.4.4 Seismic Data ………………………………………………………………… 12
1.4.5 Soil Data (see Annex XX) ………………………………………………….. 13
2 PRODUCTS ……………………………………………………………………………………. 14
2.1 Nitric Acid ………………………………………………………………………………. 14
2.2 Low Density Ammonium Nitrate Capacity ………………………………………….. 15
3 BASIC RAW MATERIAL: LIQUID AMMONIA …………………………………………….. 16

3.1 Liquid Ammonia ……………………………………………………………………….. 16
3.2 Nitric Acid ………………………………………………………………………………. 17

BASIS OF DESIGN
4 UTILITIES ………………………………………………………………………………. 17
4.1 Conditions at Battery Limit …………………………………………………………… 17
4.2 Utilities Supplies Specification ……………………………………………………. 18
4.2.1 Natural Gas Composition (MNK to provide the NG Composition in detail) 18

………………………………………………………………………….
4.2.2 Analysis of Clarified Service Water at B.L. MNK to check ……………… 19
4.2.3 Recirculated Cooling Water Analysis ……………………………………... 20
4.2.4 Demineralized Water ……………………………………………………….. . 20
4.2.5 Deaerated Boiler Feed Water (BFW): CFIh requirement from IKPT utility 20
…………………………………………………………………………...
4.2.6 Instrument Air Supply (IKPT supply to MNK) …………………………….. 21
4.3 Electric Power Supply ………………………………………………………………… 21
4.4 Velocities For Fluids …………………………………………………………………. 22
4.5 Fouling Factor for tube and shell exchanger 24
4.6 Equipment Design Pressure & Temperature
Design
5 BASIS FOR STORAGE, HANDLING OF PRODUCT, UTILITIES AND OTHER FACILITIES 25
6 EFFLUENTS …………………………………………………………………………………… 26
6.1 Liquid Effluent ………………………………………………………………………….. 26
6.2 Gaseous effluent ………………………………………………………………………. 28
7 WORKING CONDITION ……………………………………………………………………………
29
7.1 Noise Level (to be confirmed and completed by IKPT) …………………………... 29
7.2 Standard workers position and exposure time ……………………………………... 29
ANNEXURE I 31
UNITS 31
………………………………………………………………………………………………

BASIS OF DESIGN
ANNEXURE II 32
Dust and Saline Data ………………………………………………………………………..
ANNEXURE III
8 ENGINEERING STANDARDS AND REGULATION ……………………………………… 33

8.1 Introduction …………………………………………………………………………….. 34
8.2 Standardization ………………………………………………………………………... 35
8.3 System of Measurement ……………………………………………………………… 35
8.4 General Layout Condition …………………………………………………………….. 35
8.4.1 Layout ………………………………………………………………………… 35
8.4.2 Access ……………………………………………………………………….. 35
8.5 Mechanical Equipment Standards …………………………………………………... 36
8.5.1 Scope ………………………………………………... 36
8.5.2 Codes and Standard ………………………………………………………... 38
• ASME Standards ………………………………………………………. 38
• AGMA Standards ………………………………………………………. 38
• NEMA Standards ………………………………………………………. 38
8.5.3 General ……………………………………………………………………….. 38
8.5.4 Turbine ……………………………………………………………………….. 39
8.5.4.1 Steam Turbine ……………………………………………. 39
2.5.4.1.2 • Control and Protective Device ……………. 39
8,5,4 Heat Exchanger Standard…………………………………. 39
8.5.5 Steam Generation Equipment Standard 40
………………….
8.5.7 Documentation …………………………………….. 40
8.5.8 Centrifugal Pump ……………………………………………………………. 40
8.5.9 Vessels, Towers and Tanks ………………………………………………... 40
8.5.9.1 Vessels ……………………………………………………… 40
8.5.9.2 Towers ……………………………………………………… 42
8.5.9.3 Tanks ……………………………………………………….. 42

BASIS OF DESIGN
8.5.9.4 General 42
Conditions…………………………………………...
8.5.10 Non Mechanical Equipment ………………………………………………... 43
8.5.11 Fans and Blowers …………………………………………………………… 42
8.5.12 Mechanical Conveying Equipment ………………………………………… 43
8.5.12.1 Standards …………………………………………………... 43
8.5.12.2 Specific Design Requirements …………………………… 43
8.5.13 Cranes, Derricks and Hoist ………………………………………………… 45
8.5.14 Gearing and Gear Units ……………………………………………………. 45
8.5.15 Materials ……………………………………………………………………… 45
8.5.16 Noise ………………………………………………………………………….. 45
8.5.17 Effluent ……………………………………………………………………….. 45
8.5.18 Piping Loads …………………………………………………………………. 46
8.5.19 Tests ………………………………………………………………………….. 46
8.5.20 Inspections …………………………………………………………………… 47
8.5.21 Preparation for Shipment …………………………………………………… 47
8.5.22 Other Codes …………………………………………………………………. 49
8.5.23 Design for “Abnormal” Condition …………………………………………... 49
8.5.24 Non Code Equipment ……………………………………………………….. 49
8.5.25 Unproven, Protective of “First-off” Equipment ……………………………. 50
8.5.26 Miscellaneous Provisions …………………………………………………... 50
9.0 General System ……………………………………………………………………….. 51
9.1 Electrical ………………………………………………… 51
9.1.1 Reference ………………………………………………………... 51
9.1.2 Language and System of Units ………………………………... 51
9.1.3 Basic Design Consideration ……………………………………. 51
9.1.3.1 Safety ……………………………………………….. 52
9.1.3.2 Reliability ……………………………………………. 52
9.1.3.3 Simplicity of Operation …………………………….. 52

BASIS OF DESIGN
9.1.3.4 Maintenance ………………………………………... 52

9.1.3.5 Interchangeability ………………………………….. 52
9.1.3.6 Plant Expansion ……………………………………. 52
9.1.3.7 Electrical Power System …………………………... 53
9.1.4 Design ……………………………………………………………. 53
• Classification of Area ………………………………………... 53
• Basic of Design ………………………………………………. 53
• Selection of Equipment and Material ………………………. 54
• Distribution System ………………………………………….. 54
• Electrical Equipment ………………………………………… 55
• Lighting ……………………………………………………….. 59
• Wiring Method ……………………………………………….. 61
• Grounding and Lightning System ………………………….. 61
• Electrical Heat Tracing ………………………………………. 62
9.2 Instrumentation…………………………………………………………… 62
9.2.1 General Instrument Supply …………………………………….. 62
9.2.2 Supplies ………………………………………………………….. 64
9.2.2.1 General Instrumentation …………………………... 64
9.2.2.2 Control Valve ……………………………………….. 64
9.2.2.3 Other Supplies ……………………………………… 64
9.2.3 Training …………………………………………………………... 65
9.2.4 General Design ………………………………………………….. 66
9.2.5 Distributed Control System Requirements …………………… 67
9.2.6 Method of Measurement ……………………………………….. 85
9.2.6.1 Flow Measurement ………………………………… 85
9.2.6.2 Temperature Measurement ………………………. 86
9.2.6.3 Pressure Measurement …………………………… 86
9.2.6.4 Level Instruments ………………………………….. 86

BASIS OF DESIGN
9.2.6.5 Gauge Glasses …………………………………….. 86

9.2.6.6 Analyzers …………………………………………… 87
9.2.7 Control Rooms ………………………………………………….. 87
9.2.8 Control Valve …………………………………………………….. 88
9.2.9 Reference Notes for Instruments ……………………………… 89
9.2.10 Special Requirements ………………………………………….. 92
9.3 Piping Standards ……………………………………………………………. 94
9.3.1 Codes and Standards ………………………………………….. 94
9.3.2 Specifications ……………………………………………………. 96
9.3.3 Documentation ………………………………………………….. 96
9.3.4 Design Criteria …………………………………………………... 97
9.3.5 Thermal Insulation …………………………………………………………... 98
9.3.5.1Insulation above Ambient Temperature 98
……………………….
9.3.5.2 Cold Insulation 98
…………………………………………………...
9.4 Painting and Protective Coatings ………………………………………….. 99
9.4.1 General …………………………………………………………… 99
9.4.2 Buried Pipeline ………………………………………………….. 100
9.4.3 Concrete …………………………………………………………. 100
9.5 Structures and Buildings ……………………………………………………. 100
9.5.1 Site Preparation and Grating 100
9.5.2 Structural Specification …………………………………………. 101
9.5.3 Design Load ……………………………………………………... 111
9.5.4 Wind Load ……………………………………………………….. 111
9.6 Safety …………………………………………………………………………. 112
9.6.1 General …………………………………………………………… 112
9.6.2 Hazard and Operability Studies ……………………………….. 113
9.6.3 Project Boundary Standards …………………………………… 113

BASIS OF DESIGN
9.6.4 Documentation ………………………………………………….. 113

9.7 Communication System …………………………………………………….. 113

BASIS OF DESIGN
RECORD OF AMENDMENTS
It is certified that the amendments listed below have been incorporated in this copy of the publication
DOCUMENT TITLE: Design Basis for Multi Nitrotama Kimia Plant Document No.
Uprate
AMDT PARA
AMENDED SECTION DESCRIPTION OF CHANGES
NO NO
1 Sub section 3.1 Delete average values of ammonia liquid pressure to
LDAN and NA Plant BL
2 Subsection 4.1 LP steam 5K pressure change from 4.55 to 3.55

kg/cm2 g
3 Sub subsection 4.2.3 Added new row for Total Dissolved Solid at value of
2.5 mg/l
4 Section 5 All oversize and undersize prill to be recycled back to
Remelt Tank
3 Sub subsection 4.2.4 MNK-2 demin water train will comprise of one
single unit. In the event that demin water supply is
low, MNK has to cart demin water from Kujang. A
separate purchase contract of demin water will
executed by MNK
4 Sub subsection 8.5.26 • Minimum height of pipe
bridge is 7.0 meters
passing across a
mainroad, unless an
anticipation of higher
access movement.
• Minimum height of pipe
bridge on side road is
4.5 meters
• The maximum distance
between tier of pipe rack
is 2.0 meter
5 Sub subsection 1.4.5 The water table found inside the bore hole was
approximately 3.0 to 7.0 meter below the existing

BASIS OF DESIGN
ground surface
6 Sub subsection 1.4.5 Liquid limit (wL) 53 – 114
Plasticity Limit ( wP) 29 – 47
Plasticity Index 19 – 68
Bulk Density(γm) in g/cm3 1.53 – 1.79
Dry density (γd) in g/cm3 0.92 – 1.26
Equipment Design
7 Equipment Design (1) - Design Pressure &
Subsection 4.6
Temperature

BASIS OF DESIGN APPROVED YM Sheet No. 11 of 122
PROJECT: MNK -2 PROJECT SITE: CIKAMPEK, INDONESIA
ABBREVIATION
AN Ammonium Nitrate
LDAN Low Density Ammonium Nitrate
CEMA Conveying Equipment Manufacturers Association
API American Petroleum Institute
ASTM American Standard Testing Material
ASME American Society of Mechanical Engineer
ANSI American National Standard Industry
MTPD Metric Ton Per Day
NA Nitric Acid
SNI Standar Nasional Indonesia
UBC Uniform Building Code
AGMA American Gear Manufacturer Association
TEMA Tubular Exchanger Manufacturer Association
NEMA National Electrical Manufacturer Association
IEC International Electrical Code
PUIL Peraturan Umum Instalasi Listrik
ANSOL Ammonium Nitrate Solution
NFPA National Fire Protection Association
NAFM National Association of Fan Manufacturer
IP Insulation Protection
C Update changes CP SK YM 14.08.09

B Issued for re-use CP SK YM 17.07.09
2 Issued for Design CP SK YM 25.06.09
This document has been prepared by PT MNK, INDONESIA. This document is exclusive property of MNK. Unauthorized communication or reproductions not
permitted.
1. GENERAL PLANT SITE AND LOCAL CONDITION
1.1 Introduction to Proposed Plant Site
The plant site at Cikampek is an industrial estate located about 70 km

from the port of Jakarta and is approximately 25 km from the Java
Sea. PT Multi Nitrotama Kimia already operates a 100 MTPD Nitric
Acid Plant & a 120 MTPD LDAN Plant. This expansion project will be
located south of the existing facility. The area is subject to a typical
monsoon climate: hot and humid, with well-marked wet and dry
seasons corresponding to the monsoons.
Tropical cyclones occur, but are not frequent. Except for temporary
squalls, strong winds are rare. Fog is also rare. Some actual tropical
cyclone tracks through the Indonesian Archipelago. It never snows in
this region.
This Basis of Design is specific for the design, procurement and

construction of a relocated NA, new LDAN Plant, emulsion and
associated utilities and offsites.
1.2 Site Data Local Condition
1.2.1 Elevation above mean sea level : 57m

1.2.2 Nature of terrain : gentle undulation, previously
used
1.2.3 Seismic Condition : Earth Quake Zone in
accordance with SNI 1726
2002 Zone 3 equal to UBC
Zone 2A
1.3 Climatic Data
1.3.1 Rainfall Data

permitted.
Rainfall is generally rather heavy. The maximum rainfall occurs

in January, the minimum in August, the dry season goes from
May to October, the wet season from December to April.
Precipitation occurs mainly in the form of brief showers, which
often change to thunderstorms.
Maximum intensity of Rainfall over last 50 years: 100mm /h

for 2 hours
1.3.2 Barometric Pressure
Average monthly pressure at sea level varies very little at

Cikampek and from month to month.
• Design Maximum : 1013.08 mb

• Design Minimum : 999.75 mb.
Tropical cyclones are rare and occur generally in the Indian

Ocean, South of Java and Nusa Tenggara and near Timor,
between the end of March and early days of May.
1.3.3 Wind Rose
Design Wind Velocity: 33.3 m/s (120km/h) in any direction

Maximum Wind Direction (for Steel Structure building design)
Wind Pressure: 80 kg /m2
1.3.4 Ambient Temperature
Monthly mean of day maximum temperature is 35OC, whereas

monthly mean of day minimum temperature is 20 OC.
The Seasonal Data for Temperature, Dry bulb and Wet bulb
temperature as follows:
WET BULB is 29 deg C

permitted.
DRY BULB is 32 deg C related to RELATIVE HUMIDITY is 85

%
1.4 Design Data
1.4.1 Design Rainfall Data
Design rain intensity : 100 mm/h

Design rain duration : 2 hours
Specific atmospheric conditions of site which may cause

corrosion and contamination are:
• Saline air : Yes
• Dust : Yes (see Annexure – II Dust and Saline Data )
1.4.2 Design Wind Data
Regulation or code to be used for calculating wind pressure:

Uniform Building Code (UBC) and ANSI 58.1
Design wind speed/pressure to be applied in conjunction with
UBC.
Wind: 120km/h at any direction, 10m above ground level.
Wind load 80kg/m2
1.4.3 Design Air Temperature – Cooling Tower
Inlet Cooling Water to Cooling Tower 44 deg C,

Outlet Cooling Water of Cooling Tower 33 deg C
Wet bulb 29 deg C,
1.4.4 Seismic Data

permitted.
Earth Quake Zone in accordance with SNI 1726 2002 Zone 3

equal to UBC Zone 2A.
Design for seismic loads shall be in accordance SNI 1726
2002.
1.4.5 Soil Data
Soil Lithostratigraphy:
Two types of soil are found in the project site at Cikampek,
• Fine grained soils ( CH, MH) medium stiff to stiff silt,
tuffaceous silt
• Fine grained soils ( CH, ML) very stiff to very hard silt,
tuffaceous silt
Ground water condition:
The water table found inside the bore hole was approximately
3.0 to 7.0 meter below the existing ground surface.
Engineering properties:
Grain size: Percent finer by weight passing No. 200 sieve
ranged from 81 percent to 100 percent
Item
Test Unit Property
No
1 Atterberg Limit
1.1 Liquid limit (wL) percentage 53 - 114
1.2 Plasticity Limit ( wP) percentage 29 - 47
1.3 Plasticity Index percentage 19 - 68
2 Normal Test
Natural water content (wn) on
2.1 percentage 53.9 - 75.3
undisturbed sample

permitted.
2.2 Bulk Density(γm) in g/cm3 g/cm3 1.53 – 1.79

3 3
2.3 Dry density (γd) in g/cm g/cm 0.92 – 1.26
2.4 Void ratio ( e ) 1.49 – 2.077
2.5 Porosity (n) percentage 63 – 67
2.6 Degree of Saturation (Sr) percentage 90 – 100
3 Strength
3.1 Friction angle ( φ ) in degree degree 3.2 – 10.2
3.2 Cohesion ( c ) in kg/cm2 kg/cm2 0.16 - 0.63
4 Compressibility
Reconsolidation pressure/
4.1 recompression pressure ( Pc) in kg/cm2 1.03 – 7.06
kg/cm2
4.2 Compression Index (Cc) 0.45 – 1.23
Recommendation: For heavy and settlement sensitive

structures, the pile foundation is recommended. The Pre-
stressed Concrete Spun Pile is recommended with a safety
factor 2.5 to 3.0.
2. PRODUCTS
2.1 Nitric Acid
The relocated nitric acid plant was originally designed for a capacity of
250 short ton per day by Chemico of USA.

permitted.
Capacity:
Expected Product Capacity : 280 MTPD (subject to process

conditions evaluation
Expected Annual Operating Days : 350 Days
Quality:
HNO3 : 57.5 wt% min
Dissolved nitrous oxides as NO2 : ≤ 100 ppm.w
Iron as Fe : ≤ 6 ppm.w
Chloride as Cl : ≤ 10 ppm.w
2.2 Low Density Ammonium Nitrate
Capacity
Product Capacity : 300 MTPD AN prill
In normal operation, the plant is designed to produce 300MTPD of AN

Prills. In the event the prilling section is not operating, the plant shall
be capable of producing 350 MTPD of ANSOL(as 100%).
Quality:
The approximate quality of the Low Density Ammonium Nitrate as

depicted in the following table is as measured at the exit point of the
coating drum.
Parameter Quality
Moisture 0.12% max by weight
pH (measured as 10% solution) 4.7 minimum, 5.7 maximum
3
Bulk Density Between 720 and 770 kg/m
Coating agent 0.1% max by weight
Fuel Absorption 8% minimum
Mean Particle Size 95% between 1.0 mm and 2.36 mm
Crushing Strength 0.7 kg minimum (with additive) on 2 mm diameter prills

permitted.
Temperature 32°C maximum

Friability before cycling 4% max (sieve method)
Friability after 4 cycles 30% max (sieve method)
• Test methods as per CFIh BEP test methods.
ANSOL
Parameter Quality
Ammonium Nitrate 84% ±1 wt%
Concentration
pH (measured at 10% 5.5 ±0.5
solution)
3. BASIC RAW MATERIAL: LIQUID AMMONIA
Ammonia Composition:
3.1 Liquid Ammonia
Chemical name Ammonia

Common name Liquid anhydrous Ammonia
Formula NH3
Purity 98.5 %w/w min
Oil 7 ppm
Iron 1.18 pp max
H2O 1.5% w/w max
Ammonia will be available at the B.L. in the following conditions:

o 2
Temperature ( C ) Pressure ( Kg/cm )G
Min Max Avg Min Max Avg
Ammonia to 44.40
27.70 33.70 16 17.5 16.75
storage
At LDAN Plant BL 27 6.7 17.5
At NA Plant BL 27 10.9 17.5

permitted.
3.2 Nitric Acid
The Nitric Acid will be a raw material for the LDAN plant. The B/L
condition for Nitric Acid is as below:
o 2
Temperature ( C ) Pressure ( Kg/cm )G
Min Max Avg Min Max Avg
Nitric Acid 34.0 36.4 35.1 7.0 8.0 7.5
(At LDAN Plant B/L)
Chemical Composition
Sl Chemical Composition
no
1 HNO3 57.5 wt% min
2 Dissolved nitrous oxides as NO2 Max 0.01% w NO2
3 Iron as Fe < 10 ppm.w
4 Chloride as Cl < 20 ppm.w
4. Utilities
4.1 Conditions at Battery Limit
PRESSURE kg/cm2g TEMPERATURE 0C Remarks

FLUID
DESCRIPTION Minimum Normal Maximum Minimum Normal Maximum
Dew point.
Instrument Air 6.5 7.00 7.5 Ambient Ambient Ambient 0
(-) 40 C
Plant Air 6.5 7.00 7.5 Ambient Ambient Ambient
Fire Water 7.00 10 Ambient Ambient Ambient

permitted.
FLUID PRESSURE kg/cm2g TEMPERATURE 0C Remarks

DESCRIPTION
Separate
distribution
system for
Service Water 1.4 2.00 2.8 Ambient Ambient Ambient
high
pressure(prill
tower)
Separate
distribution
system for
Potable Water 1.4 2.00 2.8 Ambient Ambient Ambient
high
pressure(prill
tower)
De mineralized
7.50 Ambient Ambient 35
Water
Cooling Water
4.50 33
Supply
Cooling Water
1.02 43
Return
Boiler Feed Water 32 35.00 105
HP Steam 25 K 25.64 224
HP Steam 17K 17 330
8.0 170
MP Steam 8K
LP Steam 5K 3.55 148
LP Steam 6.00
7.50 95
Condensate
Natural Gas * 7.0 7.009 8.0 Ambient
* The composition has been provided in the following table.
4.2 Utilities Supplies Specification
4.2.1 Natural Gas Composition: Figures in Unit ; % mol, min ,max.
C1 C2 C3 n-C4 i-C4 n-C5 i-C5 C6 C7 C8 C9

min 88,3985 3,7072 1,51692 0,3698 0,3530 0,0713 0,1717 0,1246 0,0557 0,0010 0,0037

permitted.
max 92,8122 4,2335 2,46144 0,5781 0,4510 0,1097 0,2481 0,1808 0,1070 0,0111 0,0082
H2S N2 CO2 H2O S.G GHV

min 0,0000 0,6530 1,1926 0,0004 0,6244 1.066,227
max 0,0001 1,2188 3,3229 0,0018 0,6582 1.093,081
4.2.2 Analysis of Service Water at B.L.
Sl
Constituent Units Range
No
1 pH - 7.8 – 6.7
2 Turbidity NTU 5-2
3 Colour (Pt/Co) Unit 5
4 Conductivity µmhos 557 - 410
Calcium
5 ppm, CaCO3 87 – 37.3
Hardness
6 Total - Hardness ppm, CaCO3 109 – 22.3
7 M Alkalinity ppm, CaCO3 102 - 78
8 Bicarbonate ppm 169 -97
Total Chlorine,
9 ppm 0.9 – 0.00
Cl2
Sl
Constituent Units Range
No
10 Chloride, Cl ppm 32.2 - 17
11 Free- OH- ppm 4.04 – 1.29
12 Free-CO2 ppm 10.89 – 2.61
13 Nitrate, NO3 ppm 4.35 - 0
14 Sulfate, SO4 ppm 45.67 - 17
15 Sodium, Na ppm 51 - 28
16 Potassium, K ppm 10.36 - 3
17 Total Iron, Fe ppm 0.2 - 0
18 Total Silica, SiO2 ppm 75 – 11.9
19 Organic Matter ppm 7.39 - 0

permitted.
4.2.3 Recirculated Cooling Water Analysis
Sl Constituent Units Range

No
1 Calcium PPM CaCO3 150 - 350
2 Total hardness PPM CaCO3 < 500
3 Iron as Fe PPM <2
4 M-Alkalinity PPM CaCO3 100 - 400
5 Silica PPM SiO2 < 120
6 pH - 7.3 – 8.0
7 Conductivity µΩ/cm <4000
8 Turbidity NTU 20 max
9 Chloride Ppm 150 <
10 Free Chlorine Ppm 0.2 – 0.5
11 Total dissolved Mg/l < 2.5
Solids
4.2.4 Demineralized Water

No
1 pH - 6.5 – 7.0
2 Total Hardness PPM CaCO3 < 0.1
3 Silica Max. PPM SiO2 < 0.3
4 Conductivity µΩ/cm < 0.5
MNK-2 demin water train will comprise of one single unit. In

the event that demin water supply is low, MNK has to cart
demin water from Kujang. A separate purchase contract of
demin water will executed by MNK.
4.2.5 Deaerated Boiler Feed Water (BFW):

permitted.

No
1 pH - 8.0 – 9.5
2 Total Hardness PPM CaCO3 < 1.0
3 Dissolved O2 PPM w/w 0.005
4 Silica PPM as SiO2 < 0.1
5 Conductivity µΩ/cm < 0.5
4.2.6 Instrument Air Supply
Quality: Dry – oil free

Pressure : 7.5 kg/cm2g, minimum 5.5 at furthest point
Dew point : minus 40 deg C
4.2.7 Nitrogen gas

Nitrogen gas used for inert purging will be delivered on site by
LIN truck.
4.3 Electric Power Supply
Fault
Freq. Level in Motors Offsite NA &
Voltage Phase Remarks
(Hz) KA for 1 (kW) & Utility LDAN
sec.
HV 20000 3 50 40 >1000 Yes Yes -
MV 6000 3 50 30 150 Yes Yes
LV 380 3+N 50 50 ≤ 150 Yes Yes
220(AC) 1 50 9 - Yes Yes Note 1

Fault
Freq. Level in Motors Offsite NA &
Voltage Phase
(Hz) KA for 1 (kW) & Utility LDAN
sec.
110 (AC) 1 50 9 - Yes Yes Note 2
110(DC) 1 DC 9 - Yes Yes Note 3

permitted.
24 (DC) 1 DC - - Yes Yes Note 4
1. For non process services less than 0.2 KW, Lighting, Heating below
Notes: 3KW, Electrical control, Convenience socket etc.
2. UPS 110 VAC 50Hz shall be provided for Instrument circuit
3. Power for Switchgear control, control circuit for HV equipment,
emergency lighting
4. Power for field Instrument
The main power supply is 20,000 V and step down transformer(s) has to be
considered for having the supply at required voltage.
4.4 Velocities for Fluids
Recommended velocities are:
Recommended Velocity
Design Maximum
Remark
No. Service Velocity Velocity
m/sec m/sec
UTILITIES
1 Steam ( 0 - 300 Kpa a ) 10 18
2 Steam ( 300 - 5000 25 40
3 Steam Vapor under vacuum 35 40
4 Steam Vent 15 20
5 Vent on Tanks 20 22
6 Air Ducts 22 25
7 Air Filter Suction 4
8 Compressed Air 15 25
Design Maximum
No. Service Remark
Velocity Velocity
m/sec m/sec
9 Gas till 2atm 4 20
permitted.
10 Gas till 5 atm 11 35

11 Gas above 2atm >15
12 Natural gas ( 0 -3000 Kpa a ) 5 25
LIQUIDS
1 Cooling Water
pump suction 0,6 0,8
pump discharge 1.5 4
2 Boiler Feed Water
pump suction 0,5 1
pump discharge 1,5 4,5
3 Potable water installation 1 2
4 Potable water distribution 0.9 2
5 Piping for Condenser 1 2
6 Condensate Discharge Line 1 4
7 Condensate Suction Line 0.5 1
8 Filtered Water Suction Line 0.6 1.3
9 Filtered water discharge line 1.2 4
10 Fire Water Line 1.2 2.5
11 Oil 1 2
12 Fuel Oil 0,5 2
13 Demin Water Suction Line 0.6 1.3
14 Demin Water Discharge Line 1.2 4
PROCESS FLUID
1 Gaseous Ammonia 10 30
2 Liquid Ammonia 1 3
3 Ammonium Nitrate
Pump Suction 0,8 1
Pump Discharge 1,5 2,5
No. Maximum
Service Design Velocity Remark No.
Velocity
m/sec m/sec

permitted.
4 Nitric Acid
Pump Suction 0,8 1
Pump Discharge 1,2 2,5
5
4.5 Fouling factors for tube and shell heat exchangers
Minimum values
Fluid m² K / W
Boiler feed water 0.000086
Demin. water 0.000086
Steam 0.000086
Steam condensate 0.000086
Cooling water 0.0005
4.6 Equipment Design - Design Pressure & Temperature
4.6.1 Design Pressure

Design pressure and design temperature shall be in accordance
with the data sheets and shall not be lower than the stipulations
in code ASME V111 Div 1_2002 or other standards stated in the
contract.

permitted.
• Storage vessels subject to internal pressure
For storage vessels operating ≤ 50 kPa g, the design pressure

shall be selected by taking the setting tolerance of the safety
device (acc. to recommendations of the manufacturer of safety
devices) into account.( Single PSVs are allowed for, without
sparing. PSVs shall be designed to ASME V111 Div 1_2002
and API 520.)
• Pressure vessels subject to internal pressure
For maximum working pressure of up to 2000 kPa a the design

pressure shall be at least 10% higher than the maximum
working pressure for equipment protected by a safety valve.
Above 2000 kPa a the design pressure shall be at least 200 kPa
higher than the maximum operating pressure.
Pressure above 4000 kPa g shall be considered individually.
• Pressure vessels subject to external pressure
In case of external pressures, the design pressure shall be equal

to: the pressure difference, if the outside pressure is atmosheric
and fully reliable measures have been taken to prevent a higher
pressure differences.
100 kPa, if the outside pressure is atmospheric and no reliable
measures have been taken to prevent high vacuum.
110 % of the maximum pressure difference in all other cases.
Note 1: Pressure vessels mean metallic vessels with a maximum operating pressure ≥ 50
kPa g

permitted.
Note 2: The maximum operating pressure shall be the highest possible pressure during
normal operation, start-up or shutdown of the plant / unit.
Note 3: The design pressure shall be regarded as acting at the top of a pressure vessel.
Note 4: In general, vessel shall be designed for an external pressure of 110 % of the
maximum operating pressure in the jacket space.
Note 5: Whenever the enclosed fluid may reach temperatures at which the vapour
pressure is lower than the atmospheric pressure, the possibility of uncontrolled
vacuum condition in the vessel shall be investigated.
Equipment Design - Design Pressure & Temperature
4.6.2 Design Temperature
Design pressure and design temperature shall be in accordance

with the data sheets and shall not be lower than the stipulations
in code ASME V111 Div 1_2002 or other standards stated in the
contract.
For operating temperatures ≥ 0 °C, the design temperature shall

be at least 20 °C higher than the maximum operating
temperature.
For operating temperatures ≤ 0 °C, the design temperature shall

be at least equal to the minimum operating temperature.
However, the design shall not be lower than the maximum

ambient temperature.

permitted.
Note:
For equipment having two different design temperatures and a common wall
(intermediate head, jacketed or half-tube-coil equipped vessels, etc.) the design
temperature of the wall shall be unfavourable temperature.

permitted.
5. BASIS FOR STORAGE, HANDLING OF PRODUCT, UTILITIES AND OTHER

FACILITIES
Sl Storage Area Storage Philosophy

No.
1 Nitric Acid 1100 m3 ( Approx. equivalent to 3 days production
2 ANSOL 926 m3 ( Approx.) equivalent to 3 days production
AN product SILO 3* 90 t overhead silos capable of loading bulk
containers or trucks at a rate of 60 tph. From these
overhead silos a nominal 5 tonne bagging silo is to
be located inside the existing AN bagging
warehouse with a semi automatic bag loading
3
machine capable of loading at a rate of 20tph.
Additional there shall be a manual loading/ bagging
facility one tonne bulk-bag that can be used if the
semi automatic machine is not being used as well
as to bag from tote bins
4 Potable Water 2 hours
5 Filter Water 2 days
6 Demin Water 8 hours
7 Instrument Air receiver 10 minutes
8 Emulsion Maximum as per regulation
Ammonia 4 by 100 tonne vertical ammonia storage (400t) plus
allowance for an additional 2 by 100 tonne vertical
9 storage tanks. All foundations and connections for the
additional storage are to be incorporated in the design.
Oversize and undersize . All oversize and undersize prill to be recycled back to
10 Remelt Tank
Emulsion Plant capacity shall be15tph.

ANSOL Pumping capacity to load truck at 30tph
Forklifts and all mobile equipment for bagging station: MNK responsibility.
Flow of traffic around the site should be determined by IKPT and MNK based
on 6m wide ring road.
Recommended Sizes for Different Plant Building Facilities:

Sl.
Plant facility Size ( m2 )
No.
1 Work Shop 216
2 Chemical Warehouse 480
3 Guard Room 25
4 SHE Room 50
5 Office Building 600
6 Control Building 520
7 Incoming Power Station 50
8 Technical and Mechanical Store 300
9 Maintenance Office 400
10 Lube Oil Store 144
11 Weighbridge 160
Shelters to be Provided in Plant Area
12 Compressor Shed 120
Sl.
Plant facility Size ( m2 )
No.
13 Boiler Area 100
14 Demin Plant 160
6. EFFLUENTS
6.1 Liquid Effluent:
The Nitric Acid Plant and The Low Density Ammonium Nitrate Plant shall
comply with the following limits of liquid effluent. The effluent standards as per
the ministry of state for development control and living extracts No. KEP-
051/MENLH/10/1995 and SK Gubernur Jabar No 06/1999 is in the table at this
section.

Table: STANDARD OF WASTE WATER REGULATION
I. Physical Condition
0
1.Temperature < 38 C
2.Dissolved Solid < 2,000 mg/l
3.Suspended Solid < 200 mg/l
II. Chemicals (see note 1)
The maximum allowable limits for the following chemical

constituents shall be as follows:
PH 6-9
Iron no more than 5 mg/l as Fe
Manganese ″ 2 mg/l as Mn
Barium ″ 2 mg/l as Ba
Copper ″ 2 mg/l as Cu
Zinc ″ 5 mg/l as Zn
Chrome ″ 0.1 mg/l as Cr
Hexavalent
Total Chrome ″ 0.5 mg/l as Cr
Cadmium ″ 0.05 mg/l as Cd
Mercury ″ 0.002 mg/l as Hg
Lead ″ 0.1 mg/l as Pb
Tin ″ 2 mg/l as Sn
Arsenic ″ 0.1 mg/l as As
Selenium ″ 0.05 mg/l as Se
Nickel ″ 0.2 mg/l as Ni
Cobalt ″ 0.4 mg/l as Co
Cyanide ″ 0.05 mg/l as CN
Sulfide ″ 0.05 mg/l as H2S
Fluorine ″ 2 mg/l as F
Free Chlorine ″ 1 mg/l as Cl2
Ammonia ″ 1 mg/l as NH3
Nitrate “ 20 mg/l as NO3
Nitrite ″ 1 mg/l as NO2
Biological Oxygen ″ 50 mg/l
Demand (BOD)
Chemical Oxygen ″ 100 mg/l
Demand (COD)

Anionic Detergent ″ 5 mg/l

Phenol ″ 0.5 mg/l
Oil and Grease ″ 7.5 mg/l
1. Notes: The wastewater which complies with the effluent standards shall not
be diluted.
6.2 Gaseous effluent
The Nitric Acid Plant and the Low Density Ammonium Nitrate Plant will comply
with the following Gaseous effluent standard within the plant area.
Please refer to Regulatory Review Goverment Regulation PP N0.41/1999.
Gaseous Pollutant
The maximum allowable concentration of the following inorganic chemical

constituents of the emission air shall be as follows:
Sl
Chemical Concentration
No.
3
Mist sulfuric acid and/ Not more than 150 mg/Nm :
1
or SO3 or both (as SO3) -From gaseous effluent
3
Not more than 200 mg/Nm :
2 Nitrogen Oxide (as NOX)
-Gas effluent shall be colorless
3
3 Solid Particles Not more than 350 mg/Nm
3
4 Hydrogen Sulfide (as H2S) Not more than 35 mg/Nm
3
5 Ammonia (as NH3 ) Not more than 0.5 mg/Nm
3
6 Chlorine Gas (as HCL) Not more than 5 mg/Nm
3
7 Hydrogen Chloride (as HCl) Not more than 5 mg/Nm
Fluor, Hydro Fluoride Acid or 3
Not more than 10 mg/Nm
8 inorganic fluor compound
-From gas effluent
(as Hydro fluoride acid)
3
9 Lead (as Pb) Not more than 12 mg/Nm
3
10 Zinc (as Zn) Not more than 50 mg/Nm
3
11 Mercury (as Hg) Not more than 5 mg/Nm
3
12 Cadmium (as Cd) Not more than 8 mg/Nm
3
13 Arsenic (as As) Not more than 8 mg/Nm
3
14 Antimony (as Sb) Not more than 8 mg/Nm
15 Radio Nuclide Nil

7. WORKING CONDITION
7.1 Noise Level
The following noise level shall be complied within the Nitric Acid Plant and Low
Density Ammonium Nitrate Plant.
As regulation noise level at the boundary of the plant will not exceed 70 dBA in
accordance with Ministry of Environment No. 48/MEN-LH/1996
7.2 Standard Worker position and exposure time
Ministry of Labour decree no. Kep.51/MEN/1999 Para 2, stipulates:
Maximum noise level in the working area: 85 dBA

Noise level above 85 dBA shall follow the number as follow:
Please refer to Regulatory Review Doc. No. C116.3-19EG-002-Rev 1
Intensity of
Hours of Stay in a day in working area
noise in dBA
8 Hours 85
4 Hours 88
2 Hours 91
1 Hours 94
30 Minutes 97
15 Minutes 100
7,5 Minutes 103
3,75 Minutes 106
1,88 Minutes 109
0,94 Minutes 112
28,12 Seconds 115
14,06 Seconds 118
7,03 Seconds 121
3,52 Seconds 124

1,76 Seconds 127

0,88 Seconds 130
0,44 Seconds 133
0,22 Seconds 136
0,11 Seconds 139

ANNEXURE – I: UNITS
Piping Nominal
inches (inches)
Diameter
Piping Thickness Schedule (Sch)
Insulation
millimeters (mm)
Thickness
Temperature Centigrade (°C)
Capacity cubic meters (m3)
Linear Dimensions meters and millimeters (m, mm)
Pressure kg/cm2
Weight kilograms (kg)
kilogram per hour or cubic meter per hour
Flow
(kg/h, m3/h)
Surface Area square meters (m2, cm2, mm2)
Density kilograms per cubic meter (kg/m3)
Energy kilowatt hours or kilojoule (kWh or kJ)
Power Watts (W, kW, MW)
Heat Watts (kW, MW)
Heat Transfer Watts per meter square per degree
Coefficient centigrade (W/m2/°C)
Velocity Meters per second (m/s)
Noise Decibels (dBA)
Time h – hour, mt – minute, s - second

ANNEXURE – II
Result of Analysis dust and saline the boundary new plant
No Parameters Units Date

Sept,23 May,29 March,29 min max
1 Sulfur dioxide(SO2) Micro g/Nm3 17.04 24.46 16.83 17.04 24.46
2 Carbon Monoxide (CO) Micro g/Nm3 2.520 2.520 2.520 2.520 2.520
3 Nitrogen Dioxide Micro g/Nm3 20.19 16.17 20.46 17.17 20.46
4 Dust Micro g/Nm3 219 183 112 1112 219
DUST AND SALINE DATA

5 Ammonia ppm 0.09108 0.13805 1 0.09108 1
ANNEXURE – III
ENGINEERING STANDARDS AND REGULATION

8. ENGINEERING STANDARDS AND REGULATION
8.1 Introduction
This basis of design shall guide the Detail Engineering Company (DEC) to
evolve detailed design criteria which should be followed the detail engineering
stage.
8.1.1. In general where no Indonesians standards exist the design of

the equipment, materials and all other item of supply must be to
International engineering standards such as ASME, TEMA, ANSI,
NEMA, ASTM and similar American codes of practice. The DEC will
specify which codes he has used and the code or standard referenced.

Where Indonesian Standards are acceptable, MNK/IKPT would make the

standards/ codes available to the DEC.
The DEC will be permitted to use internationally recognized codes and

standards and his own “in-house” standards for those areas of the work
covered by American standards.
In such cases the tender must clearly indicate the source of such
alternative standards and, if not easily available, copies of the codes
and standards proposed must be included in the tender.
8.1.2. All references to standards, codes of practice or other design

criteria shall be taken to mean the latest edition, with any addendum of
the document available at the date of the tender.
8.1.3. The Contractor will be required to show that the equipment,

materials and all other items of supply have been chosen in such way
that they are of high standard of quality and reliability and that the
vendor of such items has an internationally recognized reputation for the
high standards of this product. MNK reserve the right to reject, without
explanation, any vendor whose products are in MNK opinion of
unsatisfactory standard.
8.2 Standardization
i. It is MNK’s intention to standardize to the maximum degree possible so

as to limit the quantity of spares held and to simplify maintenance. Thus
the DEC shall be prepared during the design period to specify wherever
possible standardization of parts.
ii. Interchangeability of component parts shall be achieved wherever

possible and standardization shall apply particularly to such items as
mechanical seals bearings, gearboxes, couplings, drum, motors valve
instruments etc.
8.3 System Of Measurement

Please refer to the Annexure- I for details
8.4 General Layout Condition
8.4.1 Layout
The DEC will be responsible for producing the Process Plant, Utilities
and off site layout with the area allocated by MNK.
8.4.1 Access
The primary consideration in arrangement of units and equipment shall

be providing an economical plant, safe and easy to maintain. The
arrangement shall favor compactness and integrated disposition of
units and equipment.
Space shall be provided around equipment for convenient operation
and maintenance access.
Access arrangement should be straight and simple. Operating and

inspection points shall be accessible and permit operating without the
use of auxiliary platforms and ladders. Equipment parts, instrument
valve hand wheels and piping shall not protrude into access aisles.
Access aisles over 7 meters long shall not be dead-ended.
The following data shall be regarded as the minimum acceptable

access distance.
Walkways, stairs & platform : Width 0.8 Meters

areas Headroom 2.1 Meters
Primary roads : Width 7.0 Meters
Headroom 9.0 Meters
Secondary access roads : Width 6 Meters

Headroom 9 Meters
Main access aisles indoors : Width 3 Meters
Headroom 3.5 Meters
Access to pump zones : 2.0 Meters
Access to heat Exchangers for
tube bundle removal
: Tube bundle length
+1.5 meters
General equipment spacing to : Min. 1.5 meters
be
Sources of ignition to : 4.5 meters
equipment
8.5 Mechanical Equipment Standards
8.5.1 Scope
The term mechanical equipment for the purpose of this specification
refers to the following units:
i. All static equipment, tank, vessel, HE, tower, column, etc.

ii. All rotating machinery
iii. All reciprocating machinery
iv. All mechanical handling and packing and associated machinery
v. All boilers and associated equipment (excluding process furnaces and
steam risers)
vi. All water and effluent treatment equipment including Force Draft and
Induce Draft cooling towers, but excluding natural draft cooling towers
and works, e.g. ponds, etc.
vii. Packaged Equipment e.g. water treatment plant, etc.
viii. Filtration and separation equipment.

8.5.2 Codes and Standards
8.5.2.1. U.S.A codes and standards shall be used throughout. The

edition current at the date of the Contract award shall rule.
8.5.2.2. The following listing of codes and standards shall be used, but
is not intended to be a complete list of such codes and
standards.
Where alternatives are shown within these codes, then the higher
quality alternative shall apply.
Codes and Standards
ASME B73.1 Centrifugal pumps

CEMA Belt Conveyors
DIN Bucket Elevator
CEMA 300 Screw Conveyor
ASME Standards
Boiler and Pressure Vessel Code Section I Power Boilers and

Section VIII Division I.
AGMA Standards
Practice for enclosed reducers or increasers using spur, helical,

herringbone and Spiral Bevel Gears.

NEMA Standards
SM 23 Steam Turbine for Mechanical Drive Service.
TEMA Standards
Heat Exchangers
8.5.3 General
8.5.3.1. It is preferable that machines should be directly coupled to their

prime movers.
8.5.3.2. For all rotating and reciprocating machines, the tensional and
flexural critical speeds shall be calculated and communicated to
MNK except as otherwise specially started, no critical speed
shall lay within 15% of the operating speed; nor, in the case of
variable speed machines, within the operating speed range nor
within 15% of maximum and minimum operating speeds.
In the case of reciprocating machines, the forces and couples

due to out-of-balance shall be communicated to MNK.
8.5.3.3. Drive Units (prime mover plus power transmission) shall have a
rated output at least 10% greater than the power requirement at
design operating conditions of the driven machine.
In all cases, the DEC shall ensure that equipment is suitable not only
for maximum operation conditions, but for start-up and any abnormal
conditions which may be foreseen.

8.5.4 Turbine
8.5.5.1. Steam Turbine
Control and Protective Device
• Conform to API 611 section 3.4.
• The turbine control valve devices shall be protected

with a corrosion resistant strainer in the steam inlet.
• Electrical alarm and trip circuit shall be normally be
energized.
8.5.5 Heat Exchanger Standards
8.5.12.2.1. The following standard shall be adopted for the design and
fabrication of heat exchangers.
ASME Boiler and Pressure Vessel Codes Section 8 Divisions I

TEMA Section R/B/C.
For air coolers, the following standard shall be adopted for their
design and fabrication: API 661.
8.5.12.2.2. The selection of materials, minimum corrosion allowances and

all design details shall be done in such a manner that the
operating life of major heat exchangers and non-replaceable
component shall be (15) fifteen years. The Bidder shall state in
his tender where in his experience shorter lifetimes would be
more economical.
8.5.6 Steam Generation Equipment Standards

8.5.9.1. The steam generation equipment shall be supplied to a proven

property design, using gas firing with reference to the following
standards.
ASME Boiler and Pressure Vessel Code

Section 1
Section 8 Divisions II
Section 9
8.5.9.2. As far as is practicable, the equipment shall be prefabricated

and pre-assembled to minimize field installation.
8.5.7 Documentation
The DEC shall supply in his Tender process and mechanical data relating to
each piece of equipment. This shall be given on a data sheet and shall include
a minimum, the process duty, operating and design conditions, material of
construction and equipment configuration, including a sketch, and shall also
include overall efficiency and utility consumption figures as appropriate.
8.5.8 Centrifugal Pump
The general standard for centrifugal pump shall conform to ASME B 73.1
8.5.9 Vessels, Towers and Tanks
8.5.9.1. Vessels
8.5.9.1.1. The following code of practice shall be adopted for

the design and fabrication of vessels and towers.
ASME Section VIII Division I. DEC will ensure
and confirm their ability to use vendors able to
specify this code on the equipment nameplate.

8.5.9.1.2. The DEC shall supply in his document process

and mechanical data relating to every vessel.
This shall be given on a data sheet and shall
include operating and design conditions, and a
sketch of the vessel showing the essential
internal, principal dimensions materials of
construction and estimated weight for the new
equipment.
8.5.9.1.3. Selection of materials; minimum corrosion

allowances standard and special design details
for all components shall be given by the DEC.
The operating life of vessels and non-replaceable
components shall be taken, as 15 years but the
DEC shall state in the document where he
considers these requirements impractical.
8.5.9.2. Towers
Any vessel whose height to diameter ratio is greater than 4:1

and which is free standing on its own support shall be designed
as a Tower i.e., a vessel subject to wind loading.
A design velocity pressure of 80 Kgs/M2 is to be assumed.
8.5.9.3. Tanks
8.5.9.3.1 The following codes of practice be adopted for the

design and fabrication of tank:
• API 620
• API 650

8.5.9.3.2 The DEC shall supply a data sheet, as defined in

section 3.6.4.1.2. For vessels, for each tank for
the new equipment.
8.5.9.4. General Conditions
8.5.9.4.1 The DEC shall show that vessels and towers of 50

tones weight or more (empty) have been
designed for the particular erection method to be
used. An outline erection method and associated
design considerations shall be given for each
vessel or tower in the category.
8.5.9.4.2 The DEC must take into account that the

maximum weight and dimensions of any item that
can be transported to the site in one piece is as
follows,
Maximum weight 80 tones

Maximum length 19 meters
Maximum width 4 meters
Maximum height 8 meters.
This height figure must take into account the

platform height of the low loading trailer, which is
included in the 8 meters.
8.5.10 Non Mechanical Equipment
Pressure vessels and heat exchangers included in package units: i.e.

water treatment plant, shall comply with the pressure vessel and heat
exchanger specification laid down in this section.
Similarly, piping, electrical equipment and instrumentation etc., shall

comply with the requirement of these specifications.

8.5.11 Fans and Blowers
8.5.11.1. The standard of the National Association of fan manufactures

(NAFM).
8.5.11.2. The standard of the America Society of Heating Ventilating and

Air Conditioning Engineers (HVACE).
8.5.11.3. In the additional to above standard, the following shall be apply:
a. Pillow block bearings shall be self-aligning type, designed for

easy replacement. For oil lubrication, sight glass shall be fitted.
b. An Anti friction bearings shall have guaranteed design lifetime
and original manufacturing
c. Coupling shall be flexible membrane type with a spacer of
reputed manufacture proven for reliable operation.
d. The rotor assembly shall be statically and dynamically balances
so that during normal running the fan operates smoothly with
vibration level measured on the bearing housing does not
exceed 3.5 mm/sec peak velocity ( unfiltered)
8.5.12 Mechanical Conveying Equipment
8.5.12.1. Standards
All conveyor shall be designed generally in accordance with the

design manual prepared by the American “Conveyor equipment
manufactures associations” (CEMA) or the equivalent
Internationally recognized standards and codes of the country of

origin.

8.5.12.2. Specific Design Requirements
8.5.12.2.1. All conveyors outside buildings shall be in

enclosed galleries aluminum sheeted.
8.5.12.2.2. All conveyors shall include structural supports,

transfers towers, all drives, pulleys, chutes,
belting, idlers, skirts, emergency switches and
protective devices.
8.5.12.2.3. Any section of conveyor over public or plant

access roads should be provided with a decking
plate under the return strand to prevent spillage.
8.5.12.2.4. All conveyors should be mounted above ground

level and a minimum headroom of 10 meters shall
be provided under all conveyor which cross public
or plant access roads.
8.5.12.2.5. Adequate stairs, walkways and platform shall be

provided on all handling equipment for ease of
access and maintenance. Conveyors carrying
combustible materials must be provided with
quenching sprays.
8.5.12.2.6. Attention must be paid to standardization in the

selection of all components.
8.5.12.2.7. The DEC must ensure that all unit parts of any
conveying system are in accordance with all other
applicable standards and codes of practice as
given in this volume.
8.5.13 Cranes, Derricks and Hoists

Shall be in accordance with ANSI (formerly ASA) standard.
8.5.14 Gearing and Gear Units
Shall be in accordance with AGMA Standards
8.5.15 Materials
Shall be in accordance with ASTM.
8.5.16 Noise
Local Indonesian standards / OSHA standard to followed
Refer to document no. C116.3-19EG-002- Rev 0
8.5.17 Effluent
The effluent disposal, which emitted from the equipment, shall comply
with the effluent and environmental requirements as specified in
section 2.3.7.
Refer to document no. C116.3-19EG-002- Rev 0
8.5.18 Piping Loads
The allowable forces and moments due to external piping or other

loads shall not exceed those given in NEMA SM 12; this shall apply for
all operating, start-up and shutdown conditions.

Supports shall be placed as close as possible to the equipment, and if

thermal expansion exists, spring hangers should be used.
8.5.19 Tests
• It is preferred than full load test be conducted on the equipment

in the manufactures work. Where this is not possible, the
equipment shall be tested within the limitation of the vendor
work service, and then a full load test shall be made after
installation at the site. For this purpose a full load test is
deemed, and special tests particular to any one type of
equipment.
• Centrifugal pump above 185 KW shall be tested in accordance
with the ASME power test code.
• All other pumps shall be tested in accordance with the standard

of the relevant ASME power Test Code.
• The velocity and displacement of the vibration at all points laid
down in the various codes and standards shall be recorded as
part of the test data.
• Further reading shall be taken during the commissioning period,
and also recorded. Refer to Vibration Velocity Measuring
Programmer 70 PEM-27 presented to the ASME plant
Engineering and Maintenance Division Conference, Fort Worth,
March 16/18, 1970, for further information.
• Where vibration are to be measured one vertical and one
horizontal element shall be provided at each main bearing. The
various monitors will be separately wired to a common junction
box mounted one the machine.
NOTE: Any deviation from the above standard shall be communicated

to MNK for discussion and final approval

8.5.20 Inspections
1. The most rigorous inspection procedures shall be applied to all

Mechanical Equipment supplied for this Project.
2. The Contractor shall supply 4 copies of his inspection

procedures with his bid and it shall include, but not limited to the
following:
• Witnessing of all test, e.g. hydrostatic crack detection, approval

of radiographs, tensile, etc.
• Checking all-important dimensions and surfaces after
machining.
• Identification of materials to code requirements.
• Dismantling inspection and reassembling of the equipment after
running and performance.
• Inspection of the equipment after packing and before final
closure of the crate, etc.
• Weld procedure and test, examination of all welds.
1. Certificates of mechanical analysis and mechanical test shall be

provided.
8.5.21 Preparation for Shipment
The equipment shall be packed for export in accordance with

instructions on packing presented elsewhere, and the preparation shall
include (but not be limited to) the following:
a. Mechanical seals to be removed appropriately labeled and

boxed.
b. Carbon seals to be removed appropriately labeled and boxed.
c. Coupling spacers to be removed, appropriately labeled and
boxed.

d. All lubricant removed, and flushed with a suitable rust

preventive fluid.
8.5.22 Other Codes
All mechanical equipment supplied under the Contract shall be in

accordance with a code or standard. Where the listed codes or
standards are unsuitable, or where the Contract proposes to deviate in
part or in total form the listed codes, or where a suitable Code and
Standards are non-existent (in which case other National or Industrial
Codes and Standards that do exist, shall be supplied) then the
Contractor shall provide details of such proposed Codes and
Standards with his Tender.
Before any equipment is designed or purchased on basis deviating

from the Codes and Standards listed in this volume of the Engineering
Standards and Regulations, MNK’s representative must be informed
and his agreement in writing to such a change must be obtained.
8.5.23 Design For “Abnormal” Conditions
The Contractor shall provide mechanical equipment that is designed to

operate under the known abnormal conditions that can occur in the
Process Plants and Services Unit and equipment of this nature.
8.5.24 Non Code Equipment
Where there are no suitable codes applicable to the equipment, then

the equipment shall be designed using the “state-of-the-art” knowledge
available at this time, and best engineering practices. In such cases,

Wherever possible, sub-units with a main unit e.g. conveyor belts for a
conveying system, shall be supplied to a Code or Standard detailed in
Bidders Tender.
8.5.25 Unproven, Protective Or “First-Off” Equipment
Such equipment is not acceptable, only proven equipment may be

used. Proven equipment is defined as equipment that has been in
continuous operation elsewhere for minimum of two years without
major breakdowns, on similar duties, and under similar conditions.
Whenever required by MNK legal or technical representative evidence

shall be disclosed in detail to prove that the equipment is acceptable.
No second or third hand request must be shown first hand evidence
and permitted to discuss the matter with actual operators of the
equipment.
8.5.26 Miscellaneous Provisions
• Mechanical equipment shall be supplied with all special tools

necessary to disassemble and assemble the unit.
• All exterior parts of the machines except finished machined
parts shall be painted with not less than one priming coat.
• The following item should be included in the manual books:
• Interchangeable part list.
• Recommended spare parts for 2 years operation
• Cross sectional drawing of machine and its part list with their
dimensions/materials.
• Maximum and minimum sleeve bearing clearance (radial and
axial).
• Maximum, minimum allowable running clearances.
• Erection, operating and maintenance instructions.
• Minimum height of pipe bridge is 7.0 meters passing across a mainroad,
unless an anticipation of higher access movement.
• Minimum height of pipe bridge on side road is 4.5 meters
• The maximum distance between tier of pipe rack is 2.0 meter
9. General System
9.1 Electrical
9.1.1 Reference
The design and installation of the electrical facilities shall conform to

the applicable portion of the latest edition of the following standards
and codes:
1. Indonesian National Standard / Standard Nasional Indonesia
(SNI) - General rules of Electrical Installation / Persyaratan
Umum Instalasi Listrik (PUIL)
2. International Electro technical Commission (IEC)
3. National Fire Protection Association (NFPA)
4. National Electrical Code (NEC)
5. Illumination Engineering Society of North America (IES)
6. National Electrical Manufacturers Association (NEMA)
7. American Petroleum Institute (API)
8. Underwrite Laboratory (UL)
Equivalent standard or code may also be accepted
9.1.2 Language and System of Units
Metric units shall be regarded as standard and shall be used in the

electrical system design. The English language shall be used for all
instruction books, drawings, certificates, and final documents except
for conduit shall be used “inch” unit.
9.1.3 Basic design Consideration

In designing the electrical system, several basic considerations which

affect the overall design shall be taken into consideration.
There are follows :
9.1.3.1. Safety
The electrical system shall be designed to ensure

personnel equipment and operational safety during
operating, inspections, and maintenance.
9.1.3.2. Reliability
Continuity of electric power supply is required for

continuous operation of the plant. The electrical system,
should be designed so that faults can be isolated with
minimal disturbance to the system, as well as providing
maximum dependability consistent with the plant
requirements.
9.1.3.3. Simplicity of Operation
Simplicity of operation is a main factor with respect to the

safe and reliable operation of a plant.
9.1.3.4. Maintenance
A well designed distribution system, with properly chosen

equipment, will reduce emergency maintenance. In
designing the system, ease of accessibility for making
inspection and repair should be considered carefully.
9.1.3.5. Interchangeability

The electrical equipment shall be designed and selected

with maximum consideration given to future
interchangeability, and also shall be simplified.
9.1.3.6. Plant Expansion
Wherever possible, general flexibility with regards to plant

expansion shall be considered in the areas of design,
Engineering, equipment selection, material utilization, and

installation of electrical facilities.
9.1.3.7. Electrical Power System
The new electrical system shall be implemented as a

separate and distinct system from
9.1.4 Design
• Classification of Area
Plant areas, in which the formation of gases, vapor, mist or dust may
occur in such quantities, that explosive mixtures with air are likely, shall
be classified as hazardous areas in accordance with the respective
regulations.
A plan of hazardous areas shall be drawn up showing the flammable

fluids, hazardous areas, temperature classes, and explosion groups.
Classification of hazardous area shall be in-accordance with NFPA No.

497 and API RP 500.
Equipment and Materials
• Basic of Design

a. The design shall be based on suitable protection of

personnel and equipment during operation and
maintenance; reliability of service; ease of maintenance;
the provision of future loads; and convenience of
operation.
b. All equipment and materials to be furnished shall be
commercially well known, proved for use in plant
applications, and designed and manufactured according to
good engineering practice.
c. The standardization of equipment and accessories shall be

stressed.
• Selection of Equipment and Materials
All equipment and material which will be installed outdoor shall be

suitable for use in a humid and tropical corrosive area and shall be
furnished with all necessary weather and anti-condensation protection
to prevent damage due to climate of fumes from the plant. All
equipment shall be suitably tropicalized to prevent the formation of
fungus and shall be suitably vermin proofed to prevent the entrance of
rats, mouse, lizard, snakes, insects, etc.
Materials, where installed at AN Plant, corrosion protection shall be

adequately protected by suitable corrosion protection system to resist
corrosion from ammonium nitrate dusting in humid environment and
corrosive atmosphere, IP 65 shall be minimum requirement for AN
Plant.
Equipment and material which will be installed indoor shall be suitable

for dust and vermin proof construction.
• Distribution System

The main electrical power supply for MNK-2 Project will be fed from 20
kV public grid / PT. PLN (Electrical State Own Company). PLN will
provide 20kV switchgear inside PLN substation for tie-in purpose.
20kV voltage will be derived to 6 kV through 20kV/6.3kV transformers.
380V supply will fed from 6 kV switchgear through 6kV/0.4kV
transformer.
For emergency power supply to the plant will be fed from the diesel
engine generator 400V.
Utilization Voltages
The following (Table 1) is the voltage system which are utilized for
MNK-2 Project.
Table.1 Utilization Voltages
UTILIZATION
CONSUMER EARTHING
VOLTAGE
Main supply from PLN 20kV, 3ph, 50Hz Low-
resistance
Motors – Less than 0.37 380V 3ph or 220V Solid
KW 1ph+N, 50 Hz
Motors – 0.37 KW up to 149 380V, 3ph, 50 Hz Solid
KW
Motors –150 KW and above 6000V, 3ph, 50 Hz Low-
resistancee
Process Heaters 380V, 3ph, 50 Hz Solid
Welding Sockets 380V, 3ph, 50 Hz Solid
Convenience Sockets (field) 220V, 1ph+N, 50 Hz Solid
Indoor Receptacle 220V, 1ph+N+E, 50 Solid
Hz
Lighting (normal + 220V, 1ph+N, 50 Hz Solid
emergency)

UTILIZATION
CONSUMER EARTHING
VOLTAGE
Anti-condensation Heaters 220V, 1ph+N, 50 Hz Solid
Diesel Engine Starter & 24V DC, 2 wire Solid/Floatin
Controls (Supplier/Vendor) g
MV and LV Switchgear 110V ,1ph+N, 50 Hz Floating
Closing and control circuits
MV & LV Switchgear 110V DC, 1ph+ N, 50 Floating
Tripping Hz
MV MCC Contactor 110 V, 1ph+N, 50 Hz Floating
Controls
LV MCC Contactor Controls 220V, 1ph+N, 50 Hz Solid
Communications systems 220V, 1ph+N, 50 Hz Floating
Fire & Gas System 110 V, 1ph+N, 50 Hz Floating
DCS 110 V, 1ph+N, 50 Hz Floating
ESD 110 V, 1ph+N, 50 Hz Floating
Voltage Profiles
The maximum permissible voltage drop along the length of the cable
with reference to the nominal supply voltage shall be as follows:
Motors 5% running at full load on motor terminal15 % on starting at

motor terminal
Feeders 5% at full load between the MCC and the load terminals
2% between MCC and a distribution board
Lighting 3% between lighting distribution board and most distant

lighting fixture
• Electrical Equipment
Power Transformer
Power transformer shall be of oil filled, ONAN, Dyn 11 vector group,

equipped with off load tap changer, suitable for outdoor installation.
Transformer rating 5000 kVA and above shall be conservator type or

N2 gas cushion type. Transformer rating below 5000 kVA shall be

hermetically sealed tank type
20 kV Disconnecting Switch (DS)
The 20 kV Disconnecting Switch will be installed near the new PLN

substation. Purpose of this Disconnecting Switch is to isolate plant
power system completely from PLN power distribution line. The
disconnecting switch will be load break type.
20 kV Switchgear
The 20 kv switchgear will be installed in the MNK-2 Project’s

substation. The 20 kv switchgear shall be of indoor, metal-clad, factory
built, free standing and withdrawable type. The switchgear shall be of
vacuum circuit breaker.
6 kV Switchgear / Motor Control Centre
The 6 kV switchgear/MCC shall be of indoor type, metal clad, factory

built, free standing and withdrawable type. The switchgear shall be of
vacuum circuit breaker. The 6 kv motor control center shall be
protected with fused vacuum contactor or vacuum circuit breaker . MV
Motor starter will be DOL (direct on line) or reduced voltage starter
type.
400V Switchgear / Motor Control Centre
The 400V switchgear shall be of a metal enclosed type, consisting of

air circuit breakers or molded case circuit breakers depending on
requirements. Low voltage motor control center shall have metal
enclosures and shall be self supporting, suitable for floor mounting.
The motor control center shall be front only or back to back type and
withdrawable type depending upon the requirements.

Emergency Power Supply System
Automatic Diesel driven Emergency Power Generation shall be

provided to the distribution system. This power supply is to be used for
essential load, such as lube oil pumps, motor operated valves, cranes,
emergency lighting, instrument, alarms, refrigeration system,
laboratory equipment and all of equipment that must be kept running
To ensure the safety personnel, equipment viable operation of the

complex on shutdown and battery charger shall also charger etc. This
power generator shall automatically start when loss of main power
occurs. The power as established for emergency shutdown shall be
used to assist in startup, particularly in the case of black start by
suitable connections to appropriate motors.
Electric Motor
Electric motor shall be NEMA MG 1 of the latest date, unless otherwise

specified and shall be suitable in corrosive and humid environment.If
required, other standard such as IECstandard also can be applied.
In, general electric motors will have the voltage supply as follows:
Special Motors (Fractional motor) may be 220V, 50 Hz 1 phase
Motors below 150 kW shall be 380V, 50 Hz 3 phase
Motors 150 kW and above shall be 6 kV, 50 Hz 3 phase
Motors 30 kW and above shall be equipped with anti condensation

heater. The space heaters shall be wired to separate out-going
terminal box. Temperature limitation shall be specified when the motor
is to be located in the hazardous area.
Motors rated up to 200 HP shall provide with class F insulation system

except where restricted by dust atmosphere. Motors rated 200 HP and
above shall be provided with class B insulation system or class F
insulation system with class B temperature rise. Insulation system
temperatures shall not exceed NEMA class B.

Motor enclosure shall be as follows:
Division I Division II Non-

Hazardous
Area
Class I Class II Class I Class II
(1) (1) (1)
Motor below Explosion Dust- TEFC TEFC TEFC
200 HP proof ignition
proof
(2) (2) (2)
Motor 200 Explosion Dust- WP2 WP2 WP2
HP and proof ignition
above proof
Note: 1) Totally enclosed fan

2) Weather Protected Type 2
3) Fractional horsepower motors rated 220 V may be TENV
Variable Speed Drive
Digitalized frequency-controlled static converter shall be used to supply

power to variable speed three-phase motors. The VSD shall be
accommodated in metal-enclosed cabinet, free standing or wall-
mounted units, suitable for indoor installation with air conditioning
room. If necessary, the VSD will be located in the control room.
The VSD will be part of MCC or separate, fed from MCC. Control &
monitoring are microprocessor-based. The input panel serves for
entering control parameters and structure pattern and installed in the
front panel of the cabinet.
The VSD is coupled to a DCS via serial interface or each signal is

transmitted via a separate signal line as specified in the data sheet.
Uninterruptible Power Supply ( UPS ) 110 V AC
The UPSshall consist of isolating transformer, rectifiers, static

inverters, bank of batteries, static changeover switches, and by pass

shielded transformer with maintenance by pass switch for alternate AC

supply. The output of UPS shall be single phase, sine wave and low
total harmonics distortion. The electric power shall be supplied from
the emergency supply line. The UPS is to be used for DCS, ESD, F &
G, etc. The battery backup time shall be considered for a period of 60
minutes.
Stationary Batteries
Stationary batteries shall be of VRLA type. Batteries shall be sealed in

containers that resistant to heat, chemical and high mechanical impact.
Stationary batteries shall be installed in racks. Batteries shall be sized
for continuous UPS for a period of 60 minutes.
Power Factor Correction
Power Factor Correction shall be employed, if required, to maintain the

power factor requirement. If necessary, capacitor banks with automatic
switching shall be employed.
Distribution board
Distribution board shall be of the metal enclosed type with molded

case circuit breakers. The enclosure shall be free standing or wall
mounted, suitable for indoor or outdoor location depending of
installation location.
Bus Duct

An isolated phase bus duct shall be provided for interconnecting power

transformer and low voltage switchgear. The low voltage bus duct shall
be of non segregated type or sandwitch type.
Bus duct shall be metal enclosed type, high current carrying capacity,
and designed for indoor and outdoor service as required.
• Lighting
General
1. Lighting systems design will generally follow as guideline

the recommendation of the illuminating Engineering
Society with respect of illumination levels.
2. In general, lighting illumination levels throughout the entire
plant shall be as recommended by IES below :
Table.2 Illumination Level
Area or Activity Iluminanc Elevation

e (Lux) (millimeter)
In door plant operating areas 100 - 200 Ground
Control Room 500 Floor
Office 500 Floor
Electrical Equipment Room 200 Floor
General Plant 30 Floor
Corridor and Stairways 100 Floor
Outdoor Stairs 15 Floor
Yards & main roads 5 -10 Ground
Laboratory 150-500 Floor
Ware House and Stock Room 50-500 Floor
Workshop 150-500 Floor
Lighting Fixtures
1. In general supplementary lighting shall be provided by fixtures

of HPS or metal halide.

2. Fluorescents fixture shall be provided for installations instrument

control room, offices, laboratories, and similar type service
buildings and outdoor areas when practicable.
Street Lighting
1. Street lighting systems shall operate at 220 Volt.

2. Street lighting systems shall be controlled by an automatic
means and shall employ HPS or metal halide fixtures mounted
on poles.
3. Street lighting poles shall be HDG steel.
• Emergency Lighting Systems
1. A lighting system shall be provided for safety purposes during

normal power outage.
2. The emergency lighting system shall be supplied in two forms
categories,
a. Category A which are include for control rooms, diesel
generator house and all other areas which must have
Immediate lighting and this supply will be trough a battery
system with continuous charging.
b. Category B which are other areas that can tolerate a short

delay in switching on. The power supply will be trough the
emergency power supply system.
3. The emergency lighting system shall be so arranged that the

failure of any individual lighting element, such as the
burning out of light bulb, cannot leave any space in total
darkness.
9.2.1.1. Wiring Method
In general, the electrical wiring system shall be above ground-

unarmored cables supported by cable trays. Underground cables when
required, such as main incoming cable 20 kV, street lighting cable,

shall be provided with mechanical damage protection (armored type

cables or un-armored with concrete trench).
Wiring for lighting system, socket outlet street lighting and flood lighting
system shall be armored type if fastened to adjacent supported
structures or installed underground, or non armored cables supported
by cable tray/conduit. Wire in conduit shall be used for building lighting
system.
9.2.1.2. Grounding & Lightning System
Grounding System
a. The electrical system ground in medium voltage (>1000 V)

distribution system shall be done by grounding the transformer star
point via a resistor.
b. The electrical system ground in low voltage (<1000 V) distribution
system shall be done by solidly grounding of the neutral conductor
or the transformer star point.
c. The instrument ground system shall be installed separately
individually.
9.2.1.3. Lightning Protection
1. Building shall be adequately shielded against lightning.

2. Any structure or other item of equipment may be considered
adequately shielded against lightning.
3. Metal-frame structures, drums or other equipment not shielded
as described above shall be grounded on at least two sides by
making connection to the grounding network, or by other
suitable means in the event that a network is not available.
4. Lightning protection shall be designed and installed in
accordance with NFPA 780.
9.2.1.4. Electric Heat Tracing

If required, electric heat tracing is used as protection against freezing,

condensation, crystallization and for heating of process fluids.
Self-regulating type heaters shall be used as electric tracers. The

power supply of self-regulating type heaters shall be 220 VAC.
9.2 Instrumentation
9.2.1 General Instrument Supply
9.2.1.1. The following information covers the general standard of

instrument supply and installation, but the Contractor shall be
responsible to provide full, adequate and complete instrumentation for
the Process Plant and Service Unit even a part of the Service Unit which
is to be supplied by MNK, so as to provide stable and accurate plant
control, safety of operation including start-up, shut-down and emergency
conditions.
9.2.1.2. The overall concept of the instrument system that the choice
will be microprocessor based distributed process control installed in the
Process Plant, Service Unit and control room.
9.2.1.3. No pneumatic instruments are to be installed in the Process

Plant and Service Unit even locally mounted. The instrumentation
system consisting of process control, computer and communication,
process simulation and shall be provided with the microprocessor based
distributed process control system with support not only digitally control
such as P.I.D. control, ratio control, on-off control, sampled data control,
cascade control, multivariable control, dead time compensation control,
feed forward control, etc, but also digital function including safety
interlock, start-up, emergency sequences, etc.
9.2.1.4. The basic requirements of the design shall conform to the latest
edition of the following:
• Instrument Society of America (ISA)

• National Electrical Code (NEC)

• National Electrical Manufacturing Association (NEMA)
• National Fire Protection Association (NFPA)
• American National Standards Institute (ANSI)
• American Standards Association (ASA)
9.2.1.5. The following additional reference codes and recommendations

to be followed are as follows:
- ISA S 5.3 : Graphic symbols for distributed

control instrumentation, logic and
computer system.
- API RP 550 : Installation of Instruments
- API RP 520 : Pressure relieving system
- API RP 526 : Flanged steel Safety valves
- ISA RP 3.2 : Flange Mounted Orifice plates
9.2.1.6. The Contractor shall submit the following documents with the
final design including but not limited to:
• P and I diagram
• Operating and maintenance manuals for each type of
instrument
• Specifications and calculations for instruments and

control equipment
• Specifications and technical information for the
distributed control system
• Configuration system instructions
• Instrument schedule
• Plot plans showing instrument locations
• Process hook-up sketches
• Schematic interlock/trip sequence diagrams
• Diagram of electric interconnections
• Diagram of temperature interconnections
• Drawing Index
• Specification Index

• Control room layout

• Operator station layout
• Specification of erection materials
• All other documentation not included above, but
necessary for purchase, erection operation and
maintenance.
9.2.2 Suppliers
9.2.5.1. General Instrumentation
The chosen supplier must be able to show that the can provide a
suitable range of electronic digital instrument, but more than one
supplier can be used of it is known that each suppliers has a premier
position in a particular area of measurement, e.g. flow measurement.
Reliability of operation availability of spare parts and not first cost must
decide the supplier(s) chosen.
The chosen supplier shall present reasonable assurances that

instrumentation system shall be brand-new product and will not be
obsoletes in the next ten years.
9.2.5.2. Control Valve
All control valves should as far as possible to chosen from one

supplier, so that some degree of standardization can be achieved.
The valves are to be pneumatically operated, and have proven
reliability, such as would be provided by “Masoneilan” or “Fisher” as a
typical supplier.
9.2.5.3. Other Supplies

In the case of simple instruments, particularly those locally mounted,

others suppliers will be considered.
9.2.3 Training
The distributed control system supplier must be prepared to train the

following MNK’s staff:
• 8 (eight) operators for familiarization of the distributed control

system.
• 3 (three) Instrument engineers for engineering and configuration
system.
• 3 (three) Maintenance Technicians.
Each person is to have a training course suitable for his level of

involvement in the instrumentation of the Project.
Instrument Engineers MNK shall be involved in preparation of system
configuration works for the Project.
9.2.4 General Design
9.2.4.1. All standards and Code used in the design of instruments and
referred to in this specification shall be the latest issue including any
revisions and additions at the date of Tender.
The distributed process control system to be supplied shall include both

hardware’s and software’s. Hardware’s for the system shall include but
not limited to Process Interface Unit, controller, input/output monitoring,
data highway transmission, Local area network communication, data
highway gateway, subsystem gateway, operator station, history module,
application module, computing module, process simulator.
The system shall make maximum application of data highway and local
area network (LAN) communication concepts to link all plant information

handling and operations data gathering and processing into one highly
accessible, coordinated system.
The system shall be microprocessor oriented system which enables

distributed control and economical optimization of advanced process
control function.
Basically, all critical devices shall be equipped with back up and

redundancy system.
9.2.4.2. All field mounted instruments specifications are to ensure the

instrument is protected from the environment where it is located,
electrical instrument in hazardous areas are to be intrinsically safe.
9.2.4.3. Transmitters are to be used shall be of Smart transmitter, which

will not be obsoletes at least for 10 (ten) years.
9.2.4.4. In all cases the instrument supplier and the main Contractor are
to select the best instrument for the particular task to be performed.
MNK reserve the right to reject a particular type of instrument or an
instrument vendor without having to give reasons for their action.
9.2.5 Distributed Control-System Requirements
9.2.5.1. The distributed Control System shall be capable of performing

both process control and management purposes through the application
of data highway and local area network (LAN).
9.2.5.2. The system shall be capable of multi-format displays such as

overview, group, detail, alarm, trend, schematic and help, message
summary, the process status and all the loop parameters such as
process variable, set-point, output, tuning constants, tag name and
service description.

9.2.5.3. The system provided shall contain the capability for process
simulation and calculation without disturbing the normal plant operation.
This feature will be used for operator training and engineering purpose
such as process optimization, etc.
9.2.5.4. The system shall provide alarm indications on the loop

parameters to advise the operator of abnormal or dangerous conditions.
The following listed features shall be available for alarm indications but
not limited to:
a. Process variable: - Low

- High
- Very low
- Very high
b. Deviation from set point
c. Controller output: - low high
Common means of acknowledgement shall be provided.

The annunciator alarms shall be able to be stored,
displayed and printed.
9.2.5.5. Input / output
The Contractor shall be responsible for supplying 24-volt DC power for

dry contact inputs, digital outputs, two wire analog inputs and outputs.
9.2.5.6. Algorithms
Algorithms, which are normally supplied with the system.
9.2.5.7. Computer System
Computer system shall be provided together with operation station.
9.2.5.8. Communication Bus/ Data Highway

The function of data highway is as link communication for transmission

digital data signal to operator station and computer system through
local area network.
Communication bus/ data highway shall have redundant cables with
associated interface and control devices. When one bus fails, the other
one shall take over automatically without any operator intervention.
9.2.5.9. Local Area Network
The Local Area Network (LAN) shall be a high-speed, bit serial,

communications bus. The LAN shall be redundant as the function of
redundancy of data highway and shall be based on the IEEE 802
standard, and shall use a proprietary taken passing protocol that
includes error checking. Operating at a minimum of five million bits per
second, the redundant LAN shall permit a virtually unlimited data
transfers base with no degradation in performance.
A fully functioning system shall require only standard software to be
operable. A functioning system shall be configurable modules.
A common set of instructions, compressing the software environment,
shall be present in every module and gateway.
The software environment shall manage all of the modules resources,

manage its use of time and memory, make sure that work gets done
on time and according to priorities, handle transfers and
communication with other modules (including those required for
redundant devices), test hardware, and diagnose faults. The base
application software shall be what each module requires to cause it to
perform its specific function.
9.2.5.10. Operator Station
Operator Station shall be capable of handling process control and

management purposes through the application of local area network
and data highway gateway.
Operator Station shall consist of at least the following items:

Operator Console
All information supplied from process-connected devices,

instrumentation subsystems, and computer system through Local Area
Network and Data Highway shall be seen and used by any operator
station.
Information shall be displayed on a high-resolution video monitor, and

displays shall be called up either by pressing one or two keys on the
keyboard. For the process operator, the operator station will provide a
consistent set of operating procedures regardless of the size of the
system, the levels of control implemented in the process, or mix of
continuous and discontinuous operations.
Using the Operator Station, the operator will monitor and control the
process, and handle process and alarm system. The operator will use
the Operator Station to display and print process history, trends, and
averages; to print reports, logs, and journals; to archive historical data
on floppy diskettes; and to monitor and change the status of equipment
system.
The process engineer will use the Operator Station to provide the
means to set-up the process database, custom display, and reports,
and to load software system from floppy diskettes.
The maintenance technician will use the Operator Station to provide

the means to see the diagnostic message that the system creates, to
diagnose such failures that the system creates, to diagnose such
failures that the system cannot diagnose itself, and to maintain
equipment in the control room and the near process.
Operator Station shall have 3 (three) operator consoles for Nitric Acid
Unit, Ammonium Nitrate Unit and Service Unit, which shall include the
following items:

• Multi-user LCD 20 inches multi-user each for

Ammonium Nitrate Unit, Ammonia Unit and Service
Unit in the identical specification and function with at
least 7 (seven) colors.
• Central Processing Units

• History Module
• Application module
• Computing module/ computer system
• Printers for data logging and reports
• Printer from alarms
• Trend recorders.
• Keyboard (key, trackball and touch screen) plus
Peripherals
Auxiliary information devices (Data Storage Devices) shall be provided

on the operator console including hardcopy peripherals, video-copier,
hardwired enunciator panels, dual diskette drives, hard disk drive/ hard
card, and mimic diagram.
In principle, all LCD should have access to all plant parameters, and
their function should be the same. This allows the operator to bring up
on different screen the same display, or to interchange function among
LCDs.
All displays should be of pre-format type and linked to actual process
parameters with fill in the blanks programming procedure.
Display operation update shall not be greater than two second.
Each Operator Console shall be capable of accessing all data on the
communication bus. Each console shall operate independently of the
other.
Failure of any Operator Console shall not interfere with the operation of
any other device on the communication bus.
Printer
The printers to be provided for general application, alarm and logging.

The color ink jet printer shall print hard copy ay text and graphic, in
display images in support of high quality, high speed workstation
display imaging.
Paper width shall be minimum of 420 mm.
The printer shall be activated automatically upon any alarm condition.
The printout of alarm conditions shall also be available upon operator

demand.
The printout shall include at least the following items:
• Tag name
• Description
• Alarm type
• Time (hour/minute/second/day/month/year) alarmed.
• Time acknowledged
• Message
The general-purpose printer is for general application such as display

copying, historical average, trend data output, system printout, etc.
Trend Recorder
Eight trend-recording pens shall be supplied for each Operator

Console. Each pen may be assignable to any point in the system,
whether it is a field input or a system calculated variable.
Data Storage Devices
Data storage devices to be provided for generation, restoration and

configuration.
Operator console shall be equipped with UPS systems and battery

charger. The capacity of battery to be provided is such that the
operator console can be fed for 1 (one) hour.
History Module

Information from any process connected devices, module, and

gateway shall be stored in the History Module, which will provide mass
storage for the control system. The information stored in the History
Module shall be displayed or printed at the operator console, for
example, or alternately will be transferred to and used in any other
LAN modules including optimization or management computer.
A history module shall also provide storage for up to 300 custom LCD
displays, in additional to all operation displays. It will also store the
databases of other modules and boxes to be used for reloading after
power failures.
Application Module
The application module shall perform calculations and control

strategies that supplement the process connected devices. The
application module will be able to access and integrate a broader
scope of process information from more than one data highway.
9.2.5.11. Controllers
Controller shall be installed near the field to minimize the electrical

signal cables.
The controller shall contain the hardware necessary to receive analog,
digital, and counter inputs from the field devices, perform control
computations according to the assigned algorithm and control
sequences, and provide the resulting analog and digital outputs to the
field devices.
Controller shall also allow:
(i) An operator at operator station to monitor, modify

process operations at the controller, (ii) A computer on the
data highway to provide set-point and output values to
controller for certain algorithm and for analog output points,

and to change the status of digital points, (iii) To provide

average and snapshot trending information to operator
station for display and logging purposes. Controller shall
be redundant system, which equipped with the
uninterrupted automatic controller (AUC) at the ratio of 1:1
plus directories.
The number of controllers is to be provided by the Contractor for the

Project shall be sufficient for handling the Nitric Acid Unit, Ammonium
Nitrate Unit and Service Unit even a part of the Service Unit will be
supplied by MNK. Controller shall be equipped with UPS systems and
battery charger. The capacity of battery to be provided is such that the
controller can be fed for 1 (one) hour.
9.2.5.12. Gateways
Gateways are the module, which interface the LAN to subsystem.

Gateways to be provided shall include:
• The data highway gateway links a data highway and a

LAN, which have different characteristics to
accommodate their different function in the system.
Process connected devices present data to the data
highway in many forms. The data highway will accept
this varied data from the data highway, convert the data
to a consistent from and increase its transmission rate
before transferring it to the LAN. Data going from the
LAN to the process will be converted by the highway
gateway to a form and rate, which is appropriate for
transmission to the destination control box.
• Subsystem gateways will be specified as appropriate to
link the LAN to instrumentation subsystem, such as
tank gauging system, analyzers, and process
chromatographs.

9.2.5.13. Data Highway Interface/ Programmable Controller
The data highway interface shall provide an interface between the

system and the programmable controllers. The interface shall be
capable of accepting several manufacture programmable controller
communications.
9.2.5.14. Power Supplies
Power supplies for modules and field instrument shall be redundant

and have at least 20% reserves for future expansion and in rush
protection capacity.
Input power-to-power supplies shall be 110 volt AC, 50 Hz from an

isolated power transformer.
Power supplies shall be backed up by at least one redundant

uninterrupted power supply with rechargeable battery. The capacity of
battery to be provided is such that all devices can be fed for 1 (one)
hour.
9.2.5.15. Power Failure/ Power System
Trip/interlock system shall be such as to ensure safety even in case of

power failure.
The power supply system shall convert supplied power to +24 V DC for
the multifunction controller and required accessories. Each device shall
be provided with self-regulatory capability to assure proper power
levels for logic, transmitter, and output requirements.
System design shall use redundant power supplies to back-up the

primary power supplies, so that the loss of an individual power supply
will not alter power system performance.
A battery back-up system shall be available to provide power to system

process connected devices including but not limited to computer

system, operator station, process simulator and controller power

supplies, upon loss of 110 V AC, 50 Hz.
The battery back-up system shall be design to switch in and out
automatically, and provide 1 (one) hour of back-up power capability.
9.2.5.16. Alarm Monitoring of Process Signal
Alarm monitoring shall be a background function, which can be

performed by each operator station, and capable of being enabled or
disabled online. Any operator station in the operating center shall have
the capability to perform the alarm monitoring.
All operator station display of process variables shall provide alarm

indication of process variables wired to controllers and Process
Interface Units. The plant overview displays, in addition to showing
alarm shall be able to provide early warning of excessive deviation of
process variables from their set points or target.
The system alarms shall have self-diagnostic capability.
The operator shall be alerted to an equipment malfunction, and from
one display shall be able to identify.
• The devices location (box address) on the
communication system.
• The type of device.
• The diagnostic code.
The communication system devices shall perform online self-checking

routines; a malfunction shall be indicated at the operate interface.
9.2.5.17. Configuration and Software System.
The Contractor shall submit a complete set of the configuration forms

with adequate instructions such as a configuration guide.
The Contractor shall be responsible for the preparation of system

configuration of the distributed control system for the Project.

The Contractor system shall have the ability to alter or configure loops
without affecting other loops on automatic control. Likewise, the
modifications or creations, or graphic displays show not effect loops on
automatic.
The software system shall be based on UNIX standard operating
system which capable of using the third party software.
The Contractor shall be responsible to provide software’s to allow tight

integration of all control function which cover a wide range of signal
conditioning, control, selection, ramping, timing, dynamic
compensation, computation, conversion, logic, alarm limit, and analysis
functions.
Powerful, “fill in the blanks” software configuration tools to be provided

in order to minimize the programming requirements. These tools shall
include a control and I/O configurations, a display configuration, and
application configurations. All operate on the same global database, so
changes in one configuration are automatically available to the others.
The Contractor shall also be responsible to provide other available

high level application packages, developed whether by vendor or not,
which shall include: report write, data historian, data validator, plant
production model, process optimizer, spreadsheet, performance
calculation, statistical packages, mathematics library, physical
properties tables, thermodynamics data, and chemical reaction
properties.
Mathematics Library
• Fast Fourier transforms

• Signal processing
• Image processing
• Vector operations
• Matrix operations

Physical Properties Library
• Steam and water

• Air
• Nitrogen
• Oxygen
• NO
• NO2
• N2O
• Hydrogen
Thermodynamic and Chemical Properties
• Equilibrium data
• Solubility
• Thermal expansion
• Joule Thomson effect
• Critical constants
• Compressibility’s
• Latent Heats
• Specific Heats
• Reaction Constants
Spreadsheet
• Shall allow data to be manipulated in row/column

format.
• Shall be able to read and write variables in the
following areas:
* Real Time Process Variables
* Accumulated Historical Data
• Shall be able to transfer data to applications programs
for processing and return the results to spreadsheet.
• Shall be limited in size only by available disk space.
Data Validator

The ability to perform context validation based on mass conservation

to Asses the possibility of measurement errors and to assign “best
guess” estimates to unknown (including unmeasured) process flows.
Consistent use of the same standard operating system structures
throughout the system, the software to be supplied shall be hardware-
independent. As a result,
The software’s function can be distributed throughout the entire plant.

The software shall also can be transported from one device to another
so as the engineers can perform any necessary programming and
configuring on a personal computer before the system is even
installed.
9.2.5.18. Diagnostic System
The distributed control system shall continuously monitor itself for

maintenance purpose and for status of its various components and
provide a means of advising the operator when a failure is detected.
Status of each module connected to the communications bus/ data
highway shall be displayed upon operator’s request.
The self-diagnostic system programs shall be capable of locating a

malfunction down to the card level for all modules and accessories
associated with the system. If any failure exists in any module
connected to the data highway, there shall be an alarm, a visual
displays and a code indicating the type of failure detected. A hardcopy
record shall also be produced.
9.2.5.19. Process Simulator
Process simulator shall be provided in order to improve the

performance of the process plant as well as for effective training of the
operators.
Process simulator to be provided shall include both hardware and
software system.

Software system to be provided shall include software licensing and

maintenance and warranty service and the right to all updates and
enhancement releases.
Process simulation software for training purposes shall include the
following items:
• General-purpose flow-sheeting package based on
equation-oriented methods.
• General-purpose data bank for different chemical,

component, equilibrium and thermodynamic.
• Dynamic real time simulating for plant wide non
linearized in working point, but rigorous model based
on the actual plant.
Process simulation software for engineering purposes shall include the

following items:
• Flow sheet simulation
• Heat exchanger rating
• Pipeline rating and sizing
• Flow sheet optimization
• Inline Fortran
• Interactive processing
Software shall be run on the microcomputer with the minimum capacity

of 2 Gbytes hard disk.
Process simulator shall be equipped with I/O interface in order to

communicate with distribution control system.
Hardwares for process simulator shall be equipped with uninterrupted

power supply plus rechargeable battery. The capacity of battery shall
be such that the process simulator hardwares can be fed for 1 (one)
hour.
9.2.5.20. Video Graphic Display

Video Graphic Projectors shall be capable for use in correlation of

Plant Process and Utilities flows with instrumentation. These projectors
shall be suitably angled as necessary to make close viewing easy.
The visual display of the video graphic projectors shall be of colored so

can be arranged as to be readily revised later if necessary. Provision
shall be made on alarm system that visual display of video graphic
projectors shall have capability to indicate in which parts of location of
the graphic, originated the alarm.
9.2.5.21. Auxiliary Instrumentation
The auxiliary instrumentation system shall consist of hardwired

annunciators; interlock shutdown system, analog instruments and
other auxiliary instruments.
1. Hardwired Annunciators
• Important alarm, such as shutdown, shall be
generated by the hardwired annunciator units, and
not by the DCS.
• Annunciator indicators shall be grouped on the
auxiliary console, close to their associated
operator station.
2. Emergency Shutdown System

• Emergency shutdown system for major equipment
or major process units as per P & ID’s shall be
implemented by Programmable Logic Controller.
• Startup bypass switches Emergency Shutdown
System etc. requiring operator intervention shall
be provided for each system located on the
auxiliary console mentioned before.
• Maintenance override switches shall be installed in
the Emergency Shutdown System Racks located
in outstations.
3. Logic Control System

The discrete control function of DCS shall perform

automatic sequences and interlock to ensure proper
operation of the electromechanical equipment.
The discrete control function system shall provide:

• Automatic operation of field equipment
• Start-stop of the pumps, motors, air actuated and

motorized operating valves (MOV)
• Protection against hazardous operating conditions,
checking of safety parameters and initiation of the
corresponding alarms.
4. Analog Instrument
• Auxiliary analog instruments, (e.g., mv/I converter,

RTD/I converters), shall be mounted in auxiliary
instrument rack and shall be provided as required.
• Where the process licensor specify “a record”
and/or “a totalize” digital storage method to be
undertaken by the DCS, not dedicated hardwired
recorders or totalizers, shall be provided.
5. Others
• Marshaling racks with interface terminated

between field and control room shall be installed in
each outstation for process and racks rooms.
• Instrument/electric interface relay racks shall be
provided for conditioning of digital input/output.
• Power distribution panels shall be installed in each
outstation and rack room. Transformers may be
furnished with the panel to provide the required
voltage to meet the equipment requirements, if
necessary.

• Special recorders for analyzers shall be installed

on the analyzer racks in outstation or racks room.
• DCS manufacturer shall furnish DCS package
with: ergonomic operator chairs; ergonomic
supervisor tables.
• The control room’s floor shall be of raised floor
type.
9.2.5.22. Local Panels
1. Local panels shall be enclosed, self-supporting

cubicle type panels, suitably gasketed to render them
dust and moisture proof. Sun-shades/weather hoods
shall be provided over local panels. Localized hoods
over annunciators shall be considered to prevent
glare on the annunciator legends.
2. Where local panels contain relay and/or alarm logic
system, consideration shall be given to the climatic
conditions. A common group alarm shall be provided
in the control room, if the annunciator is given on the
local panel.
3. Where the size of the cubicle would be
disproportionate to the requirement, open panels with
weather protective cover can be considered.
4. All pneumatic tubing inside the panel shall be 1/4” OD
(should be 304 SS ) tubing.
5. All panels shall be constructed regarding to area
classification. Purging and pressurizing air (2.54 mm
WG) may apply to meet the electrical hazardous
condition if required. However, such protection shall
be minimized so as to minimize the maintenance
work.
6. Instrument panel shall generally be console or flat-
faced type with underground interconnections.

7. Color of instrument panels shall be defined during the

detailed engineering stage.
8. Al least 20% spare panel space shall be provided.
9. The instruments shall be accommodated side by side
in four (4) rows on each panel. Auxiliary instrument
shall be installed in auxiliary racks or instruments
panel racks.
10. For connection terminals to outside, terminal strips
shall be provided on lower section of panel inside.
11. The ventilation fan may be installed on the upper-side
of each panel, when required.
12. Nameplates shall be provided for those instruments,

which are installed on the panel. They shall, as a rule,
be located just beneath each instrument.
13. Each nameplate shall have the instrument Tag
Number and service designation written in English.
14. The nameplate shall be made of clear plastic plate,
black letter, white ground and black engraved.
15. Each terminal shall be provided with tag plate having
its terminal number.
9.2.5.23. Wiring
a. All field-mounted panels and cubicles shall have

button cable entry.
b. All wiring to/from the panel shall employ a terminal
block, which is located on panel frame for connection
to the panel and the wires shall be laid in PVC duct.
c. Wiring over short distances between the PVC ducts
and the instrument termination blocks shall be
protected by:
• Plastic trucking ; or
• Spiral round vinyl protective strips, as appropriate.

d. Wire size shall generally be minimum 1.13 square

mm stranded with PVC insulation except for any
vendor’s special wiring requirements and for power
cables.
e. The color of PVC wire sheath shall be as follows
except for any vendor’s special wiring requirements.
a. AC 110 V. Red (AC power)

Black (neutral)
b. AC 220 V. Red (AC power)
Black (neutral)
c. DC 125 Brown (+)
Blue (-)
d. DC 24 V. Gray (+)
White (-)
e. Grounding Green
f. RTD Black
White
Red
g. 2 wire (4-20 mA), Gray (+)
1-5 V. (pulse) White (-)
h. T/C Yellow (type K)
Red
Black (type R)
Red
9.2.5.24. Power Distribution
a. All switches shall be grouped and mounted on their

respective panels, the main switch alone shall be an
non- fuse breaker.

b. Electric power for electric instrument, analyzer,

temperature instruments, relay unit and annunciators
shall be fed separately in the panel. Individual
isolation shall be provided for each control loop.
c. All switches shall be housed in a switch box, which is
installed at the upper position of each panel where
one switch shall be provided for each loop individually
and each switch shall have its nameplate.
All make and break contacts shall be hermetically

sealed as much as possible, regarded of electrical
classification, to ensure proper operation in refinery
atmospheres. This requirement is to minimize open
contacts.
9.2.5.25. Method of Measurement
9.2.5.1. Flow Measurement:
Orifice plates should be generally used, but pitot tubes,

ventures, rotameters, corriolis, magnetic flow meters or
vortex meters can be used if improved performance can
be shown.
Positive displacements meters are to be used for

totalizing flow in this device are necessary. Flow
integrator loops for material balances, are to be
compensated for temperature and pressure changes as
required.
Variable area meters of the plug type or specially

calibrated orifice and piping 1 1/2” NPS or less. Non-
contacting flow measurement shall be used for severely
corrosive service and for materials of high viscosity.
Flow instruments in carbonate solution service shall be
provided with a flushing system to prevent plugging, or
non-contact flow meter.

Temperature and pressure must be measured upstream of

metering devices, if such conditions frequently alter.
9.2.5.2. Temperature Measurement
In general thermocouples shall be used for

measurement, but where greater accuracy is required
resistance thermometers are to be used.
Filled-system devices on dial thermometers can be used

for local mounting care should be taken that location of
thermo wells should be in the mainstream of the fluid to
be measured.
9.2.5.3. Pressure Measurement
Pressure instrument measuring elements are preferable

to the Bourdon tube type but bellows type or diaphragm
type can be acceptable if the service so requires.
Element shall be of stainless steel or such other
corrosion resistant material as the conditions dictate.
9.2.5.4. Level Instruments
In general the primary element for fluid level

measurement in equipment is to be of the differential
pressure diaphragm type, but the external cage
displacement type can be used, or in the case of
difficulty process conditions differential pressure dip
tubes can be considered. In large liquid storage tanks
tape and float type instruments are preferred. The
instrument chosen should be accurate to within a
tolerance of 0.1% to 0.3%.
9.2.5.5. Gauge Glasses

Where gauge glasses are fitted to tanks or vessels, they

shall be “armored through vision” type or “armored
reflex glass” type gauge glasses in steam services
above 21 kg/cm2g shall provided with mica shield. The
maximum length of gauge glass shall be 2 meters and
each connection to vessel shall be fitted with isolating
valve and drain valve.
Gauge glasses shall be connected to the distributed
control system through subsystem gateway.
9.2.5.6. Analyzers
All sample points shall be provided with analytical

instruments.
Analytical instruments for continuous measurement will
be selected from manufactures with a proven record of
successful application. Particular attention will be paid to
sampling system to ensure the provision of clean fluid
samples to analyzers where desirable, analyzer will be
field mounted to minimize sample line length and in the
cases adequate housing provision will be made for
analyzers.
All analyzers shall have indication in the field and shall
be connected to the distributed control system.
9.2.7 Control Rooms
Design and location:
1. The control rooms shall be always located as far as possible, in a

area which cannot be reached by hazardous, corrosive, and toxic
on anxious dust, gases or vapors. When this is not possible a
system of pressurized ventilation with humidity and temperature
controlled dust free air input into the control rooms is to be
provided.

2. The control rooms shall include operator station room, computer

system room, process simulator room and kitchen room.
3. The control rooms shall be equipped with air condition devices to
control temperature and humidity.
4. Air condition devices shall maintain the control room at the
temperature and the humidity decided by instrument’s vendor.
The air conditioning system shall have the standby unit of 100%
cooling capacity.
9.2.8 Control Valve
9.3.2.1. All control valve are to be pneumatically operated
9.3.2.2. Material of construction shall be to a specification not

less than pipeline specification, valves shall have austenitic
stainless steel trim or better dependent on the duty and shall
preferable be tight shut-off.
Valves should be rated to a minimum of 300 lb if flanged

and 600 lb if screwed.
9.3.2.3. Where conditions such as size, duty and process

characteristic permit all control valves shall be of the rotating
sleeve port-opening type, otherwise they can be of globe type
with port sized to pass double flow.
Body sizes smaller than 25 mm should be avoided if

possible, and for valves smaller then this a reduced trim
should be used.
9.3.2.4. The discharge characteristic of control valves shall

wherever possible be of linear change or equal percentage
characteristic.

9.2.8 Reference-Notes for Instruments
Transmitters bodies shall be 316 Stainless steel
Rotameters
Rotameters of glass tube type are not acceptable.
Level Transmitters
Transmitter bodies shall be 316 Stainless Steel

Gauge Glasses
1. Gauge chamber and other metal component parts in contact with

carbon dioxide mixture or other corrosive fluids shall be
constructed op ANSI type 316 stainless steel.
2. Unless otherwise specified, material of construction for gauge
chambers and other metal components shall be carbon steel or
higher quality.
3. Each gauge glass column shall be factory assembled.
Self-Operating Pressure Regulators
Control valve shall be furnished with plugs seating from the top in
order to facilitate removal in the field. Actuator shall be either “direct”
or “reverse” acting to satisfy “fail safe” requirements.
Pressure Switches
1. Switches shall be suitable for use in a general purpose for indoor

area
Direct connected pressure switch shall be suitable for outdoor
installation in Class I group D, Division 2.
2. Contacts shall be SPDT rated at 5A min at 110 VAC (Volt AC), 50

Hz.

3. Set points shall be factory adjusted. Adjustments shall be tamper

proof from outside the case. Set points shall be adjustable over
the entire instrument range.
Flow Integrator
1. Integrator shall be 6 digits, non reset-able.

2. Yoke mounted integrator shall be suitable for outdoor service in-
tropical area.
Self Operating Control Valve
1. Valves shall have composition diaphragm and steel diaphragm

casings.
2. Valves shall be furnished with external process pressure
connections.
Butterfly Control Valve
Where valve positioners are specified, vendor shall utilize 316SS

tubing when connecting to valves positioners and actuators. All
exposed joint (or union connecting) shall be coated with epoxy or
wrapped with PVC tape.
Globe Type Control Valve
1. Control valve, which are furnished with solenoid valves shall be

integrally mounted and piped by the control valve manufacturer.
Solenoid valves shall be “Three Way” type with nickel-plated

brass bodies and 1/2” NPT integral threaded connections and soft
seats.
Solenoid valve shall be the type of class “B” temperature,

continuous duty in class I, Group D. Division 2 semi hazardous
location. Solenoid valves shall be weatherproof and explosion
proof and suitable for outdoor installation. It shall be provided with

manually reset latching device, which shall hold the valve in the
normal reenergized position unless it is electrically tripped.
Manual resetting of the solenoid valve will not be possible unless
it is restored to its “normal” (reenergized) position.
Dials on pressure gauges furnished with positioners, air sets, etc.

shall be graduated in Kg/Cm2.
2. Valve for medium pressure steam shall be furnished with 440 0C

hardened inner valve and 316 Stainless Steel ring satellite faced
Pressure Gauge
1. Pressure connections shall be as follow:

a. 1/2” NPT for gauge
b. 1/4” NPT for diaphragm sealing devices
2. Diaphragm seal shall be suitable for use in respective services in

which it is used.
Thermocouple Type Alarm Switches
1. The temperature measurement (in M.V.) shall be compared to a

mill volt reference voltage.
The deference shall be amplified to actuate an alarm contact at
certain preset value. The Unit shall incorporate automatic cold
junction.
The input impedance shall be approximately 50,000 ohms or
higher.
2. The alarm set points shall be adjustable over the entire range.
3. Switch enclosure shall be suitable for rack mounting in a general-
purpose area.
4. Switch contact shall be SPDT normally closed and rated at 5
AMP minimums.

Temperature Transmitter
Thermo well material shall be 316 Stainless Steel for C.S, and SS
lines services, unless otherwise specified.
Direct Connected Filled System
1. Each instrument shall consist of a filled system temperature-

sensing element.
2. Sensing bulb and capillary tubing of the filled system shall be
made of 316 Stainless Steel.
3. Gas filled thermal systems, where specified, shall be case
compensated for ambient temperature and barometric pressure.
4. Liquid filled thermal systems, where specified, shall be fully
compensated.
5. Filled thermal system shall have bendable extensions and
adjustable unions.
EMF to Converter
1. The measuring means shall incorporate automatic circuit

compensation for variations in cold junction temperature. It shall
also incorporate thermocouple extension lead wire for all internal
wiring to extent necessary to place through cold junction
temperature at a point where the temperature is equal to that of
the cold junction-compensating coil.
2. EMF to converters shall be furnished with thermocouple burn out
features. On thermocouple failure, converter output shall drive in
the un-scale direction.
3. Thermocouple lead lengths shall be on average of 200 meters.
Where required, the converter manufacturer shall supply
compensation for such lead length.

9.2.10 Special Requirements
1. Thermocouple for the primary temperature measuring elements

shall use magnesium oxide (MgO) filled type.
The important measuring point shall adopt thermocouple with the

least time lag.
Transmitters functioning alarm and/or interlocking shall be
independent from transmitters functioning controlling and
measuring.
2. Copper, brass, bronze, aluminum and aluminum alloys shall not
be used in fabrication of component parts that will be in contact
with the process medium. In addition, these materials shall not be
used for non-process applications where exposed the materials
are protected with an effective cover e.g. PVC.
3. In the ammonia transfer systems a remote operated emergency
shut off valve shall be located between the storage tank and the
ammonia transfer pumps is additions to the manual shut off valve.
4. Meters for measuring flow of ammonia liquid shall be of a turbine
meter type.
Careful consideration shall be given to the location of the meters
as required to prevent formation of vapor in the meter.
The turbine flow metering system shall be provided with a digital
indication of totalized flow.
5. Level instrumentation for Ammonia Storage shall consist of
flanged nozzle located near the base of the tank, a shut off valve
and a DP cell.
6. The signal from the cell shall be used for local indication and also
transmitted to central operator station.
7. The Contractor shall provide a spare nozzle and valve adjacent to
the first nozzle.
8. Compressor shall be provided with a local control panel
incorporates adequate instrumentation located adjacent to the
compressor set.

9. The compressor shall be completely controlled from central

operator station with full instrumentation and annunciation
system.
10. All automatic trips shall be provided with facilities to enable the
trip to be by passed if desired but this by pass shall not be
capable of accidental or unauthorized operations. Any trip so by
passed shall be clearly indicated by visual signal in the central
operator station.
11. Compressors and turbine shall be provided with complete

instrumentation with dual probes, to measure vibration and axial
thrust at each bearing.
Key Phase arrangement to facilities vibration analysis shall be
provided.
This shall be done as per API Standard 670 non-contacting
vibration and axial position monitoring system.
All vibration monitors of probes shall be available in the central
operator station.
Axial position monitors and vibration alarm enunciators shall be
available on both local and the central operator station.
12. The operating speed of centrifugal compressor shall be indicated
both on the local compressor panel and in the central operator
station.
9.3 Piping Standards

9.3.1 Codes and Standards
The Bidder must allow for all piping, valves and fittings to accord with
the American standards are given below but not limited to:
- ANSI B.31.3 Chemical plant and refinery piping
- ANSI B.36.10 CS pipe dimensions
- ANSI B.36.19 SS pipe dimensions
- ANSI B.16.5 Flanges 150-2500
- ANSI B.16.11 Dimensions of steel socket and screwed fittings
- ANSI B.16.9 Dimensions of steel butt weld fittings
- ANSI B.16.20 Non-metallic gaskets
- API 601 Spiral Wound Gasket

Design of flanges and butt weld end steel and alloy
- API 600
gate valves.
- ANSI B.16.10 Face to face dimensions of flanged valves.
- ANSI B.1.1 Unfired inch screw threads (UN and UNR thread form)
- ANSI B.1.20.1 Pipe threads
- ANSI B.16.21 Non-metallic flat gaskets for pipe flanges
- ANSI B.16.47 Large diameter carbon steel flanges
- API 5L Line pipe
- API 6D Ball valves

API 594
Check valves
- API 598 Valve inspection and testing
- API 599 Steel plug valve
- API 602 Steel gate valve
- API 608 Metal ball valve
- API 609 Butterfly valve
9.3.2 Specifications
The Contractor shall submit all specifications to MNK. These

specifications shall include, but not limited to the following:
• Basic piping design criteria

• Detailed piping material specification
• Shop fabricated piping and piping installation
• Color coding
• Details of all special item e.g. separators, steam trap etc.
• Surface coatings and protection of underground pipe work.
9.3.3 Documentation
Documents to be supplied by Contractor shall include but not limited

to:
9.3.3.1. Fully dimensional plot plan locating all units, items of

equipment, steel work etc.
9.3.3.2. Plant piping general arrangement drawing with a key

plan showing relationship of all arrangement drawings.
9.3.3.3. Scale for general arrangement drawing of Process

Plants and Services Unit 1:25
9.3.2.5. All line designation list indicating each line with its route,
design and normal operating pressure and temperatures.The
fluid, line size, schedule and specification insulation if any.
9.3.2.6. A schedule for painting requirements

9.3.2.7. As built drawings of
• Plot Plant
• Underground services
• Drains and Sewers
9.3.2.8. Bills of materials and material requisitions.
9.3.4 Design Criteria
9.3.4.1. These design criteria shall apply when situations are not
covered by the latest issue of codes and standards quoted in
section 3.7.3.1. above.
9.3.4.2. “Inside Plot” piping should be overhead wherever

possible, whereas “outside Plot” (off-site) piping should normally
be at grade level in concrete sleepers, but may be carried
overhead for process, economic or access requirements.
9.3.4.3. Pocket or low points should be avoided in piping

arrangement; Drains and vents are to be provided in low and
high points respectively.
9.3.4.4. Underground piping should be avoided as far as

possible. Where it is necessary to locate process piping below
ground it should be tarred. However, if pipes are insulated or
traced then they are to be installed in trenches, which will be
covered with loose concrete covers.

Line placed in trenches must be on concrete sleepers and have

adequate spacing all round for easy maintenance.
9.3.4.5. Adequate provision shall be made on pipe rack for

routing of main electrical cables and in all cases
overhead pipe racks must have a minimum clearance of
3 meters above grade level.
9.3.5 Thermal Insulation
9.3.5.1. Insulation Above Ambient Temperature
9.3.5. 1.1. The insulation materials shall be suitable for use

within the Project and also suitable for use in a
tropical environment.
9.3.5. 1.2. The design of the insulation shall be based on the

following data:
9.3.5. 1.3. Design lifetime 5 years

Ambient design temperature 33 OC max.
Limiting external surface temperature 55 OC max.
The external surface is to be clad with aluminum
foil, sealed against ingress of moisture.
9.3.5.2. Cold Insulation

In addition to the requirements listed above for hot
insulation, insulation for heat gain i.e. refrigerant or cold
process piping will be required.
The insulation used must prevent the ingress of

moisture and the cold metal surface must be coated

with dense bit mastic paint before application of the

insulation.
9.4 Painting and Protective Coatings
9.4.1 General
9.4.1.1. The DEC must consider protection for carbon steel or

low alloy steel surface where necessary either by painting or
other surface coatings, which must be suitable for use in a
tropical environment.
9.4.1.2. The protective system chosen should have a design

lifetime of 5 years and consideration and great care must be
given to the preparation of surfaces before covering are applied.
9.4.1.3. Where painting is to be employed as a surface coating

consideration should be given to the following specification as a
guide line:
• A priming coat of red lead
• A undercoat of zinc filled paint
• A final coat of eliminated rubber paint
The color of the final coat, where large surfaces are concerned,
should take account of the possibility of minimizing the Sol-air
temperature.
9.4.1.4. Proprietary item are, as far as possible to be finish

painted by vendor with a system to meet the requirement of
clauses 3.7.5.1.1, 3.7.5.1.2 and 3.7.5.1.3 above.
9.4.1.5. Item fabrication from carbon or low alloy steel which

specifically are not coated but where corrosion may be a

problem prior to commissioning, shall be treated with a

temporary protective coating which shall have a life expectancy
at least equal to the schedule transportation / erection time.
9.4.2 Buried Pipelines
Buried pipe systems if any should be protected by use of heavy duty

filled tape wrap system.
9.4.2 Concrete
Consideration shall be given to means of preventing attack of concrete.
9.5 Structures and Buildings
9.5.1 Site Preparation and Grading
The site for the Project was prepared along with the Existing Plant.
Based on the soil investigation conducted by MNK necessary cut and
fill and compactness will be done by Contractor in accordance with
ASTM D-1557-70.
The site will be graded and generally finished with an elevation of

+57.00 meters above MSL.
Based on such information from MNK, Contractor will develop design

criteria and prepare the detailed construction drawings, as defined
elsewhere in the Contract.
Contractor shall provide within its Lump Sum Fixed Price for site
preparation including, but not limited to the following items:

1. Final site grading and removal of surplus material to a section

determined by MNK but assumed to be not more than 1 kilometer
from the Site
2. Temporary roads, shoulders and surfacing
3. Permanent roads, shoulders and surfacing
4. Hard standing and paved area
5. Gravel areas
6. Surface drainage ditches
7. Underground drainage lines
8. Underground chemical sewer lines
9. Culverts
10. Underground pipe-sleeves
11. Grade bridge pipe crossings
12. Temporary underground piping and cables
13. Temporary and permanent fence
14. Temporary facilities
15. Temporary Fence and Permanent Fence
16. Other pertinent requirement
9.5.2 Structural Specification
Designs
All designs shall be based on the Codes, Specification and Standards

referred to herein.
Contractor’s designs may use other codes, specifications and

standards which they have found from experience to be appropriate
providing these are not less stringent than those referred to herein.
Contractor’s design shall be based on the following codes,
specification and standards, latest editions.
a. SSPC - Steel Structures Painting Council.
b. ASTM - American Society of Testing Materials
c. AISC - American Institute of Steel Construction
d. ACI - American Concrete Institute
e. UBC - Uniform Building Code

f. ANSI - American National Standard Institute

g. SNI - Standar Nasional Indonesia
h. SII - Standar Industri Indonesia
(Indonesian Industry Standards)
i. PMI - Peraturan Muatan Indonesia
(Indonesian Load Standard Regulations)
j. PPKGURG - Pedoman Perencanaan Ketahanan Gempa untuk
Rumah dan Gedung (Indonesian Earthquake Standard)
Foundations
Foundations shall be generally spread footing/mat. However

Contractor can use piling or a combination of piling and spread
footing/mat for large loads such as prilling tower, reactor and
compressor houses, if economic.
Structural Steel
Structural steel materials shall conform to SNI 03-1729-2002 or ASTM-

A36,or JIS G3101, SS-41 or equivalent with a minimum yield stress
Fy = 2,400 Kg/cm2, and designed in accordance with AISC and UBS.
Connection Bolt for Structural Steel
Connection bolts for main framing members shall be high strength bolt
conforming to ASTM A 325 or equivalent. Connection bolts for
secondary member (joist, purling, girt, etc.) shall be ordinary structural
bolt conforming to ASTMA A 307 or equivalent.
Contractor shall provide and periodically update as the design

progresses the total estimated quantities of structural steel, as a check
by MNK for the following:
a. Each Process Unit
b. Service Unit
c. Miscellaneous Structures
d. Buildings
e. Others

Concrete
a. Concrete shall conform to ACI 318 and UBS. Concrete for

foundation and general work shall be an average compressive
strength of 3000 psi (210 Kg/cm2) at 28 days. Concrete to upper
structure of prilling tower, road and pavement shall have an
average compressive strength of 4000 psi (280 Kg/cm2) at 28
days. Concrete for leveling shall have an average compressive
strength of 1850 psi (130 Kg/cm2) at 28 days. Concrete for
prestressed concrete shall have an average compressive strength
of 7250 psi at 28 days.
b. The compressive strength of concrete at 28 days shall be
monitored by cylinder test.
c. Cement shall conform to ASTM C150 and be type-I for all
concrete.
d. Reinforcement bars for concrete shall conform to SNI 07-2052-
2002 or ASTM A 615 and have minimum yield strength of
60.000 psi.
e. Prestressing tendons for prestressed concrete shall conform to
ASTM A 421, ASTM A 416 or ASTM A 722 and have the
minimum tensile and yield strength stipulated in referenced ASTM
specifications.
f. Steel wire fabric reinforcement shall conform to ASTM A 185.
g. Concrete aggregate shall conform to ASTM C 33.
Concrete Foundations and Concrete Structures
a. Specifications, material quantities, and concrete foundation

construction drawings for shallow spread footings and raft type
foundations for all plant, equipment, structures and buildings
supported at grade.
b. Specifications, material quantities and construction design.
Drawing for all reinforced concrete structures, above and below
grade, of plans, elevations, sections and details.

c. Specifications, materials quantities and design/construction

drawing for reinforced concrete structures for all equipments and
items of supply of a special nature such as compressor, clarifier,
settling pond, if any.
d. Specifications and design/construction drawing shall, in additional
to the Project design parameters include the specific design
requirement.
e. Concrete foundations and concrete structure construction
drawings referred to above, including reinforcement bar bending
schedules, shall be clear and complete and show all pertinent
requirements and information such as, but not limited to,
dimensioned locations of members, size/ spacing/ location of
reinforcement, size/ location/ Projection of anchor bolts, details of
concrete inserts, pockets, and type of surface treatment/ finish to
permit rapid and easy construction.
f. Detailed design calculations for each concrete structure which
shall clearly show design assumptions and/or design parameters,
load/forces and references to section of the code/ standard on
which the design are based.
g. As above for all other civil engineering work including paving and
temporary facilities.
Contractor shall prepare and periodically upgrade as design

progresses the estimated quantities of concrete, as check by MNK, for
following:
a. Foundations for each process plant and Service Unit.

b. Concrete superstructures for Each Process Unit and Service Unit.
c. Paved areas
d. Roads
e. Miscellaneous concrete
f. Temporary facilities
Structural Steel Buildings
a. Design drawings for each structural building required. The design

drawings shall consist of plans, elevations, sections and details,

which define completely the building design forces and member

sizes/weights to permit a structural steel fabricator to calculate
design stresses and detail, supply and fabricate the building
structural steel requirements. In case of existing buildings
extensions the design shall be standard with the existing and
drawings shall show any modification required to the building as it
is before extensions.
b. Detailed design calculations except for fabricators detailed
calculations for each building, which shall clearly/show design
assumption and/or design parameters, load/forces and references
to section of the code/standard on which the design are based.
c. Check vendor’s calculations for shop details and shop
erection/detail drawings to ensure correct interpretation of design
drawings, specifications and schedule for each building. This shall
not relieve the vendor from complying with its responsibilities to
perform in accordance with the terms of its Contract.
d. Prepare general specifications for erection of structural steel
buildings.
Standard Prefabricated Buildings
a. Sketch plans, elevations, sections and details for structural steel

building types, which can be supplied under the category of
standard prefabricated buildings. The sketches shall define
completely the building requirements to permit the supply of
standard prefabricated buildings of dimensions most closely
approximating specified building sizes.
b. Basic information on these sketches shall include only major
dimensions and elevation, windows and doors, and related
appurtenances as are illustrated in vendor’s catalogs.
c. General specification for design and construction materials for
standard prefabricated buildings, which shall provide specific
Project design parameters and identify vendor’s standards.
d. Specification for the erection of standard prefabricated buildings.
e. Check vendor’s design calculation and erection/detail drawings to
ensure correct interpretation of sketches, specification and
schedule for each building. This shall not relieve the vendor from

complying with its responsibilities to perform in accordance with

the terms of its Contract.
Miscellaneous Steel Framed Buildings
a. Buildings shall be steel framed structures clad with industrial

aluminum corrugate sheet 3003-H 14, 0.7 mm minimum thickness
and fixed with stainless steel fasteners with neoprene washers.
b. Sheeting at gables, eaves and around all opening shall be
enclosed with aluminum flashing or performed neoprene closure
strips to ensure watertight finish against rain.
c. Aluminum framing, where provided, shall be 6061-T6 Alloys.
d. Natural lighting shall be provided in roof and walls by reinforced
polyester resin glass panel’s 1.6 meters width to match light
transmission of approximately 50%, spaced in a range to avoid
propagation of fire.
e. Buildings shall have natural ventilation through louvers and roof
ventilators.
f. Each building shall have air-conditioned offices as required.
g. External doors shall be of flat aluminum sheet construction with
minimum sheet thickness of 4.5 mm and anodized exposed
surfaces of 0.02 mm minimum thickness.
h. Internal doors shall be first grade local hardwood, except in
process areas.
i. Roll up doors shall be galvanized steel chain operated type.
j. Glazed openings in doors shall be fitted with 6 mm thick-wired
plate glass.
k. Gutters shall be sheet aluminum of 2.3 mm minimum thickness.
Down pipes shall be PVC of manufactures standard thickness
and circular in cross section.
Architectural Type Building: General
a. Select and appoint an Indonesian Architect to prepare

architectural design and specifications for buildings specified
elsewhere herein as being of “architectural” type such as control

building and laboratory as well as offices inside other buildings

and small buildings such as local substations.
b. General specification for materials and outline drawings for each
building of the type referred to above consisting of plans,
elevations, sections and details all of which shall completely
define the building requirements including utilities, air conditioning
and materials, and the nature, size and locations of facilities to be
housed in these buildings such as control panels and electrical
control gear.
c. The Architect shall prepare detailed materials specifications and

complete design/construction drawings for the selected buildings,
including bills of materials, estimate of cost, and other technical
data required by Contractor.
d. Check Architect’s material specifications, design calculations,
design/construction drawing and material quantities to ensure
correct interpretation of the requirements specified by the
Contractor. This shall not relieve the Architect from complying
with its responsibilities to perform in accordance with the terms of
its Contract.
Detailed Requirements
a. Control, laboratory, office and substation buildings shall be

concrete block construction with roof, floors and columns of
concrete and walls of concrete block. Roof shall be of 4 percent
slopping.
Insulation shall be 50 mm thick Fresco board or other approved

equal incombustible material having a no capillary structure and
resistant to fungi’s growth.
The warehouse roof insulation shall be designed as well as the
temperature in the warehouse relatively constant all the time.
b. Windows shall be aluminum Projected or fixed sash. Windows in

air-conditioned buildings and offices shall have double panes.

c. Exposed surfaces of sash shall be a clear anodized finish of 0.02

mm minimum thickness.
d. Hardware shall be white bronze or other approved equal type.
e. External doors shall be of flat aluminum sheet construction with
minimum sheet thickness of 4.5 mm and anodized exposed
surfaces of 0.02 mm minimum thickness.
f. Internal doors shall be of first grade local hardwood.
g. Internal glazed partitions shall be of first grade local hardwood.
h. Floor shall be finished with ceramic tiles.
i. Control room and laboratory shall be ventilated at the rate of 6
and 10 air changes per hour, respectively. Hood air requirements
may be considered as a part of the total ventilation air.
j. Office ventilation shall be based on the number of occupants and
other heat sources.
Steel Structures
Structure below a height of 5.000 meters from finished grade shall be

reinforced concrete for reduction in maintenance, unless Contractor
can demonstrate clear economic advantage for using structural steel.
Structures above a height of 5,000 meters from finished grade shall be

structural steel unless Contractor considers there are advantages in
using reinforced concrete either because of suitability for process
conditions, overall job reduction costs or greater facility construction.
Specification and design drawings for structural steel structures

consisting of plans, elevation, section and details which define
completely the structure(s) requirements including, but not limited to,
dimensions, elevations, member sizes/weight, location of
fixed/removable handrail, stairs, ladder, equipment framing/ floor cut-
outs, type(s) of flooring, hoist/crane, equipment support connection,
member forces/ reactions/moments and column anchor bolts to permit
a structural steel fabricator to design detail and prepare shop drawings,
supply and fabricate the structural steel structures.

Dead, live, wind, earthquake and operating loads for supported

equipment shall be listed on the design drawings or appropriate
calculations.
Contractor shall assume that for special equipment, such as conveyor

galleries and related structural steel will form part of the Contractors
design and supply the structural steel necessary to support the special
equipment on the structural steel structure.
Detailed design calculations for each structure, which clearly show

design assumption and/or design parameters, load/forces and
references to section of the code/ standard on which the design are
based.
Check vendor’s calculations for shop details and shop erection/detail

drawings to ensure correct interpretation of design drawings,
specifications and schedule for each structure. This shall not relieve
the vendor from complying with its responsibilities to perform in
accordance with the terms of its Contract.
Miscellaneous Structural Steel Platform/Attachments
Specifications and design for all miscellaneous structural steel

platform/attachments supported on or connected to major vessels and
equipment.
The design drawing shall consist of plans, elevations, sections and

details which define completely the platform/attachment including, but
not limited to, dimensions, loads/forces, member sizes/weight,
handrail, ladders, stairs, type of flooring, brackets, davits, hoists, etc. to
permit a structural steel fabricator to design detail and prepare shop
drawings, supply and fabricate the steel requirements for the
platform/attachments.
Detail design calculation where standard design is not used for each
platform/attachment which shall clearly show design assumption

and/or design parameters, load/forces and references to section of the

code/standard on which the designs are based.
Check vendor’s calculations for shop details and shop erection/detail

drawings to ensure correct interpretation of design drawings,
specifications and schedule for each platform/attachment. This shall
not relieve the vendor from complying with is responsibilities to perform
in accordance with the terms of its Contract.
Specific Requirements
a. Flooring for process structures shall be galvanized open grate
type steel.
b. Bar thickness and depth shall be suitable for its intended services
and loads with acceptable deflections.
c. Stair treads shall be standard type open grating with non-slip
nosing and galvanized.
d. All steel work shall be adequately protected by suitable paint
system to resist corrosion from urea dusting in humid
environment and corrosive atmosphere.
Siding for Building
Siding for all buildings shall be extended to a practical level above the
operating floor(s) to provide good protections to the operating floor and
operators against heavy driving rains.
Siding all extend from 2.0 m above floor level to the eaves.
The lower 0.5 m above plant level shall be made of bricks.
Road and Drainage
Road throughout the plant area shall be of reinforced concrete

construction.
Road shall be designed for 20 tons truck or 150 tons crane.

Width of plant roads shall be 10 meters for primary and 7.5 meters for
the secondary roads minimum.
Underground pipeline passing under roads shall be protected either by

concrete encasement pipe sleeves or designed for road loads,
including construction equipment and crane loads, likely to pass over
it.
Contractor shall conduct necessary tests along the proposed roads to

assure that the design and construction to be adopted such as slab
thickness and sub-grade preparation, will meet the loading
requirement.
Surface run off and drainage shall be based on precipitation intensity

of 100 mm per hour of rainfall.
Surface drainage ditches for surface run-off shall be located on each

side of all roads.
Minimum depth of open ditches shall be 30 cm.
Surface run-off coefficient shall be as follows:

• Concrete paved and road : 0.85
• Roof : 0.9
• Gravel surfacing : 0.4
• Graded area : 0.2
Surface drainage ditches and underground sewers shall be directed

into the final discharge point designated by MNK.
Contractor shall ensure that contaminated surface water and other

plant effluent are not discharged, without prior treatment to the final
discharge point.
The process sewer lines shall be PVC, Coal tar epoxy and C.I pipe
depending on the type of service.

Toilets should be provided with two kinds of eastern and western type.
Individual septic tanks to be provided for each building with suitable

chlorination arrangement and overflows to be connected to the sanitary
sewer.
The sanitary sewer lines shall be PVC pipe.
9.5.3 Design Load
Seismic Loads
All critical structures shall be designed as per zone 3 SNI 1726-2002,

which is equal to Zone 2A in UBC.
9.5.4 Wind Loads
Design for wind loads shall be in accordance with UBC and ANSI 58.1.
Basic design wind velocity shall be 120 Km/Hour.
Inspection Requirements
Inspection shall follow the testing procedure specified in ASTM C-192.
9.7 Safety
9.7.1 General
The Project must be designed on the basis of reasonable minimum

capital cost and excessive automation must not be included with the

intention of saving labor, nevertheless, due regard must be paid to the

design and the quality of equipment to ensure the complete safety and
reliability in the operations of all sections of the Project at all times
including start-up and shut-down.
Attentions must also be paid to the working conditions in buildings with

respect to temperatures, adequate ventilation and maximum sound
levels.
The Contractor must show that every part of the design of the Project
with regard to safety of operation for both personnel and equipment is
in accordance with the requirements laid down by the Occupational
Safety and Health Administration (OSHA) of the United State of
America or the Health and Safety Organization of the United Kingdom
of such other codes of practice of internationally recognized bodies
concerned with safety in the chemical industry.
9.72 Hazard and Operability Studies
MNK requires that “Hazard and Operability Studies” on all parts of the
Project as may be required by Project or by any Local or National
Authorities having the right to require such studies.
9.6.3 Project Boundary Standards
The noise level is so controlled that the noise level at the boundary of
the Project will not exceed 55 dB (A) for more than 10% of any hourly
time period.
9.6.4 Documentation

The Bidder shall include on his Tender, a site layout plot plan giving
the estimated noise level continuous at intervals of 10 dB (A) between
85 dB (A) and 55 dB (A) for the whole of the site of the Project.
The Contractor shall provide the following documentation at the design

stage.
1. Noise data for individual items of equipment and ant proposed

noise control measures.
2. A report giving the estimated sound level in each area, details of
any noise control measures, a table of the exposure of personnel
to noise and an estimate of the noise levels at the boundary of the
Project for discussion with the Local Authorities.
9.7 Communication System
9.7.1 Telephone
The Contractor shall prepare and supply all equipment of the

telephone system including but not limited to:
• Telephone
• Cable and cable road
• Junction box
The Contractor shall prepare and supply paging system including but
not limited to amplifier, microphone, cable, load speaker, alarm and
other equipment.



C116-10EMD-001 - Rev C - BASIS OF DESIGN

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C116-10EMD-001 - Rev C - BASIS OF DESIGN

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PT MULTI NITROT AM A KIMIA

PREPARED CP Doc. No. C116-10EMD-001

PROJECT DATA, SITE DATA, UTILITY DATA,

C Update Changes CP SK YM 14.08.09

1 GENERAL PLANT SITE AND LOCAL CONDITION ……………………………………… 10

3 BASIC RAW MATERIAL: LIQUID AMMONIA …………………………………………….. 16

C Update Changes CP SK YM 14.08.09

4.2.1 Natural Gas Composition (MNK to provide the NG Composition in detail) 18

C Update Changes CP SK YM 14.08.09

8 ENGINEERING STANDARDS AND REGULATION ……………………………………… 33

C Update Changes CP SK YM 14.08.09

C Update Changes CP SK YM 14.08.09

9.1.3.4 Maintenance ………………………………………... 52

C Update Changes CP SK YM 14.08.09

9.2.6.5 Gauge Glasses …………………………………….. 86

C Update Changes CP SK YM 14.08.09

9.6.4 Documentation ………………………………………………….. 113

C Update Changes CP SK YM 14.08.09

2 Subsection 4.1 LP steam 5K pressure change from 4.55 to 3.55

C Update Changes CP SK YM 14.08.09

C Update Changes CP SK YM 14.08.09

DATE 14.08.09 Rev. No. C

PROJECT: MNK -2 PROJECT SITE: CIKAMPEK, INDONESIA

C Update changes CP SK YM 14.08.09

DATE 14.08.09 Rev. No. C

PROJECT: MNK -2 PROJECT SITE: CIKAMPEK, INDONESIA

1. GENERAL PLANT SITE AND LOCAL CONDITION

1.1 Introduction to Proposed Plant Site

The plant site at Cikampek is an industrial estate located about 70 km

This Basis of Design is specific for the design, procurement and

1.2 Site Data Local Condition

1.2.1 Elevation above mean sea level : 57m

1.3 Climatic Data

1.3.1 Rainfall Data

C Update changes CP SK YM 14.08.09

DATE 14.08.09 Rev. No. C

PROJECT: MNK -2 PROJECT SITE: CIKAMPEK, INDONESIA

Rainfall is generally rather heavy. The maximum rainfall occurs

Maximum intensity of Rainfall over last 50 years: 100mm /h

1.3.2 Barometric Pressure

Average monthly pressure at sea level varies very little at

• Design Maximum : 1013.08 mb

Tropical cyclones are rare and occur generally in the Indian

1.3.3 Wind Rose

Design Wind Velocity: 33.3 m/s (120km/h) in any direction

1.3.4 Ambient Temperature

Monthly mean of day maximum temperature is 35OC, whereas

WET BULB is 29 deg C

DATE 14.08.09 Rev. No. C

PROJECT: MNK -2 PROJECT SITE: CIKAMPEK, INDONESIA

DRY BULB is 32 deg C related to RELATIVE HUMIDITY is 85

1.4 Design Data

1.4.1 Design Rainfall Data

Design rain intensity : 100 mm/h

Specific atmospheric conditions of site which may cause

1.4.2 Design Wind Data

Regulation or code to be used for calculating wind pressure:

1.4.3 Design Air Temperature – Cooling Tower

Inlet Cooling Water to Cooling Tower 44 deg C,

1.4.4 Seismic Data

C Update changes CP SK YM 14.08.09

DATE 14.08.09 Rev. No. C

PROJECT: MNK -2 PROJECT SITE: CIKAMPEK, INDONESIA