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1、Project ReportPage 2 of -1Tomkins PLCIndex No:CC1750Project Name:Gates Unitta Power Transmission Suzhou FactoryProject Name: International Rectifier (Xian) PlantInternational Rectifier (Xian) Co., LtdIndex No:CC132494 Zhuque StreetAccount No:1-34196Xian,Shanxi Province 710061Date of Report:18 March
2、2004Peoples Republic of ChinaReport By:Fred Cai, Fei LongConference With:Mr. Qin Siliang, Deputy General ManagerExecutive Summary:Subject: Project Monthly Report No. 1 March 2004This letter is to document the key issues of the progress of this project. Any items which we have previously agreed upon
3、or otherwise decided will not be completed are not covered in this letter. Such items should still receive the attention agreed upon as discussed in our previous monthly reports and correspondence.As requested by Mr. Qin, FM Global loss prevention requirements, which have been discussed in last few
4、months, are listed in the report.This report is strictly informational and is intended to reduce the possibility of loss to property insured by Factory Mutual Insurance Company by bringing to your attention certain potential hazards and/or conditions. It does not imply that all other hazards or cond
5、itions are under control. You must make the decision on whether and how to address any hazard or condition. The liability of Factory Mutual Insurance Company is limited to that contained in its insurance policies. No liability or policy coverage is created by reason of this report or the inspection
6、upon which it is based.Key Hazard Highlights:Present Hazards: Accumulations of combustible building materials, wooden forms and scaffolding, scrap lumber, paper and, plastic packing and wrappings, and other refuse appear at new locations daily. The fire danger is increased further by the presence of
7、 many ignition sources, such as hot work equipment, carelessly discarded matches or cigarettes; temporary heaters and lights etc. The number of wind losses to buildings under construction was approximately equal to the number of fire losses. Building framing, roof covering and walls are easily blown
8、 down by moderate winds, before they are anchored or tied together. Qualified contractor should be assigned to conduct steel structure installation.Future Hazards:Project ReportPage 3 of 12International Rectifier (Xian) Co., LtdIndex No:CC1324Project Name:International Rectifier (Xian) Plant Plastic
9、 containers and packaging material used in the production area are combustible. The heat release rate can be three to five times greater for plastic material than for a similar arrangement of ordinary combustibles. In addition, burning plastics release dense corrosive smoke which can cause severe pr
10、operty damage in a semiconductor backend plant. The factory will be located in the earthquake prone zone. The earthquake would cause distortion of production equipments, flammable gas pipes and electrical cable break, even collapse of the building. This will result in significant proper damage and b
11、usiness interruption. Adequate seismic protection should be provided for the equipment and pipes/cables.Action Required:Construction:Steel deck roof system design drawings including detailed information of components should be provided for review.Automatic Protection:Reportedly, the sprinkler design
12、 drawings have been revised. I would like to review the updated design drawings.Processes / Equipment:See Attachment.Upcoming Activities:Project ReportPage 11 of 12International Rectifier (Xian) Co., LtdIndex No:CC1324Project Name:International Rectifier (Xian) PlantThe plan review comments provided
13、 before will be discussed in the project meeting on 29 March 2004. I would like to review the updated design drawings at that time.Photos / Attachments:Summary of Loss Prevention Comments and Discussion ResultsConstructionThe steel frame design drawings of Phase I plant building were submitted by CN
14、ME.1. Only non combustible materials or FM Global Research approved foam insulation materials should be used on the building construction. Unapproved plastic foam materials such as polystyrene, polyurethane or polyisocyanurate whether in the form of sandwich panels, insulation layers, wall facing or
15、 otherwise should not be used in any part of the construction.The insulation below the steel deck roof and insulation of steel panel walls will be fibre glass. Gypsum board will be installed on the internal side of the Phase I building. This will be acceptable.2. The roof should be designed to withs
16、tand the dead load plus the more restrictive of the balanced or unbalanced snow load, the rain load and other superimposed live loads. In general, the minimum design live load should be 1.0 KN/sq m (20 psf). If a lower design live load is chosen, the resultant minimum roof design live load should be
17、 greater than the balanced snow loading of 0.23 KN/sq m in Xian and instability due to rainfall ponding should be precluded.As shown in design drawing 10015.JG1.1, the roof design live load will be 1.0 KN/sq m. This will be acceptable.According to local design code and land survey report issued by l
18、ocal survey company, the 50-yr snow load will be 0.25 KN/sq m and the new facility will be located in Modified Mercalli intensity VII area. These are used in the structural design and will be acceptable. (shown in JG1.1)3. The metal roof should be designed to provide adequate uplift resistance for a
19、 3-second gust wind speed of 40 m/s (90 mph). Based on the roof slope of five degrees and the roof height of 7.2 m (24 ft) at eave, building wide 100 m (328 ft), minimum 1.0 m (3 ft) of parapet around the roof perimeter, our calculations for wind uplift resistance shown that the roof should be capab
20、le of withstanding the following loads for wind, balance on a maximum 0.9 sq m effective area:Field: 1.1 Kpa (22 psf) 1.0 KpaPerimeter: 1.9 Kpa (38 psf) 1.7 KpaCorner: 1.9 KPa (38 psf) 1.7 KpaThe width of the perimeter strip 3.0 m (10 ft)The above calculations are for your reference and are subject
21、to change if any construction feature is changed.Roof system design has not been reviewed.(need to solve through purchasing spec. Calculation based on 85 mph instead of 90 mph. Wind loads should be changed accordingly.Roof height is no more than 7.00 mts. 4. The roof drainage system should be adequa
22、tely designed for the 100-year maximum hourly rainfall density which is 65 mm/hour in Xian area per local code.Rainfall density of 175 mm/h will be used to design the roof drainage system which is significantly higher than FM Global requirement. This will be acceptable. In addition, emergency overfl
23、ow scuppers will be provided in the parapets and will be shown in the next version design drawings. This will be reviewed when the detail drawings are available.5. The Main Building should be elevated to 0.3 m above higher than outside road level. No basement or below-grade occupancies should be inc
24、luded in the Main building as well as the Utility Building, Office Building.As confirmed by CNME, the finished floor elevation of the Phase I Building will be 300 mm higher than the yard road elevation. This will be acceptable.6. Several pipe trenches will be located in the building. The bottom of t
25、he trenches will be 1 m below the grade. The designer indicated that the leak of underground pipe will damage the stability of the soil under the building foundation due the special soil condition in Xian. These trenches should be provided to the drain the spilled water from the underground pipes to
26、 outside inspection manhole. Therefore, the openings on the exterior walls below the grade will not be sealed.In this case, a plant emergence plan should be developed to seal these openings, when the water accumulation on the site is going to be higher than the finished floor level. Process and Equi
27、pment7. Adequately-sized Emergency Generators should be provided and connected to the critical process equipment, such as, the fume exhaust system for solder dipping process, DI water system, chiller system and vacuum pump system.Reportedly, the emergency generator will be able to provide adequate p
28、ower supply for the critical process equipment, such as, the fume exhaust system for solder dipping process, DI water system, chiller system and vacuum pump system. This will be acceptable.8. An adequately-sized backup transformer should be provided.9. The cold room construction material should be e
29、ither non-combustible or FM approved foam material. Unapproved combustible foam plastic material should not be used. The AHU equipment construction material should be either non-combustible or FM approved foam material. Unapproved combustible foam plastic material should not be used.Non-combustible
30、material will be used in AHU equipment. The insulation material of ducts and pipes will be non-combustible material and FM approved foam plastic material. The solder dip machine exhaust ducts will be made of galvanized steel panel. This will be acceptable. But cold room construction material has not
31、 been decided.10. The FM approved HEPA filter should be used in the clean room AHU system.This is not applicable, because the cleaning classification of the production area does not require HEPA filter.11. For the forming gas process:a. An excess flow valve, or an excess flow switch connected to the
32、 emergency shutoff valve, should be provided on all hydrogen cylinders, located as close to the cylinder connection as possible. In addition to this shutoff valve, a restrictive flow orifice (RFO) should be provided in the gas cylinder valve body. For all process gases, the RFO should be sized at 0.
33、25 mm unless a larger orifice is needed to meet process demands.b. An FM approved automatic shut-off valve should be installed in the main hydrogen feed pipe. This should be interlocked to shut off the hydrogen supply in case of hydrogen leakage or fire alarm.c. Since Xian is located in a severe ear
34、thquake area, seismic protection should be provided on the flammable gas and liquid supply pipe system to cut off supplies in an earthquake.The excess flow valve or excess flow switch, restrictive flow orifice (RFO), automatic shut-off valve and seismic shutoff valve for hydrogen system will be cons
35、idered by your company. The seismic shutoff valve on natural gas supply main will be considered.12. For the hydraulic molding process, automatic devices should be provided for shutting off the hydraulic oil pumps in the event of a fire on hydraulically operated molding machines with reservoirs of fl
36、ammable hydraulic oil. This could achieve through an interlock to the sprinkler system or detection system.Manual operated shutoff switches will be installed beside exit doors to shut down the hydraulic molding machine in the emergency situation. Automatic shutoff of hydraulic oil pump will not be i
37、nstalled.13. We recommend the boiler room should be located away from the main building to limit the chances of the boiler exhaust fumes being taken into the clean room makeup air and damaging the clean room environment.This will be done.14. Fuel burner safeguards on the boilers should be in line wi
38、th FM Global standards. Details will be provided later.As Mr. Qin mentioned, that either “Weishaupt” gas burner which is made in Germany or “Riello” gas burner which made in Italy will be used for steam boilers. According to the specification, both of burners consist of automatic shutoff valves, tig
39、htness proof, flame detectors and combustion safety guards. Generally, these are acceptable, however, the vender should confirm the automatic safety control system can meet FM requirement.Fire Protection15. Yard hydrant system a. Yard hydrants should be provided with a spacing of no more than 90 m.
40、The hydrant should be fed by an underground loop.Site layout is not available.b. Ductile iron pipe with cement lining is one option for the sprinkler and hydrant yard loop service main. If the ductile iron pipes are used, properly designed thrust blocks should be provided where pipes change directio
41、n such as elbows, tees and dead ends.All underground pipes will be installed in the treches.c. The yard hydrant should be capable of providing 500 gpm at 20 psi (1900 l/min at 1.4 bars) minimum water demand using a 150 mm underground yard loop inside the plant. This should be fed from aboveground lo
42、cal made hydrant pumps sized at 1900 l/min at 5.0 bar, taking suction from a 250 cu m aboveground tank.The public water system flow test result shows poor water supply capacity. The yard hydrant system will be supply by fire pump taking suction from water tank. This will be acceptable.16. The automa
43、tic sprinkler systems should be fed by an aboveground FM approved diesel engine driven fire pump rated at 5700 l/min at 8.6 bar (1500 gpm at 125 psi) taking suction from an aboveground tank with at least 350 cu m reserved for sprinkler.One FM approved diesel engine driven turbine type pump (95 l/s 7
44、.0 bar) will be installed to feed sprinkler system. An underground 600 cu m water tank will be built for fire protection system.17. We recommend that an adequately sized underground loop should be provided around the Phase I building for the sprinkler system.I suggest providing a loop system of unde
45、rground sprinkler water supply mains for future expansion, instead of installing a single pipe through the Phase I building. The loop system with divisional valves can help to mitigate the impairment of fire protection system due to pipe leakage and maintenance, especially, there will be more than t
46、wo sprinkler risers in this location after the expansion in the future. In addition, underground pipe system can reduce the water damage potential in the earthquake.18. Based on the information we have on the storage and process, we would like to provide the sprinkler design criteria as follows per
47、FM Standards:a. FM Approved quick response sprinkler heads at a temperature rating of 68 to 74 degree C with 15 mm orifice should be installed in the production, test laboratory and CUB area. The sprinkler should be designed to discharge a density of 8 mm/min over the hydraulically most remote area
48、of 280 sq m (0.20 gpm/min over 3000 sq ft).As confirmed by your company, the production area will be 100k clean area. FM approved standard sprinklers (68 deg C) can be used in production area, instead of using quick response sprinklers.b. FM Approved standard sprinkler heads at a temperature rating of 68 degree C with 15 mm orifice should be installed in the office, canteen area. The sprinkler should be designed to discharge a density of 4 mm/min over the hydraulically most remote area o