Utilities: build the backbone once, add modules with the presses; four-module boiler hall and chiller compound

Phased build list for steam, cooling and hydraulics (launch, Duplex 1,
Duplex 2, Classic, options): everything cheap to oversize and costly to
retrofit (rooms, pads, headers and ring mains with a valved branch per
press position, tanks, HX frame, feeders, one sequencer) is built for the
five-press fleet at launch; boilers, chillers and hydraulic pump sets come
in identical modules as presses arrive. The Single 2.1 aggregate is
proposed as the first central pump set; per-branch isolation and filters.

Rooms sized for four modules each (user decision, estimates until vendor
footprints): boiler hall ~18 x 9 m for four 500 kg/h positions (fired case,
AIX DZL0.5 body), open screened chiller compound ~12.5 x 10.8 m with four
pads (250 kW at 40 C ~ Carrier 30RB 080-090), ~40 m2 pump and HX room; the
cooling tower pad of the water-cooled concept is dropped. Yard 178 -> ~379
m2. Four boilers carry ~8 presses with N+1; four 250 kW chillers carry the
five presses with CH-4 as reserve and no growth position unless the pads
take the ~350 kW frame (RFQ option).

- scale.md: yard table and basis, utility phasing section
- pressing-line.md: hydraulics phasing and re-quote questions
- steam-cooling.html: B-4 position, phasing and rooms card, details, RFQ
  questions (pw_sc_check clean)
- construction RFQ: yard table, sealed area 6,549 m2 (68 %)
- total-investment: added-scope row +73k to +122k USD (building rate on
  the ~200 m2 the yard grows by)
- Payap parts model: yard rebuilt from Params (blr_n, blr_inst, ch_*,
  bh_*, cy_*, pr_*), renders updated

docs/equipment/pressing-line.md

@@ -51,6 +51,20 @@ automated candidate). What it means:
   trench along the press rows. Open for the re-quote (below): whether the
   Single 2.1's own aggregate becomes part of the central plant or a
   standby, and whether the Classic can run from it.
+
+  Built to grow from one press (October 2026): the plant room is built at
+  full size, and the hydraulic and air ring mains are sized for the whole
+  fleet from the start, with a valved, capped tee at every press position,
+  the empty ones included, so a new press is connected without stopping
+  the others. The proposal for the Single 2.1's own aggregate, already
+  sized for the second press, is to set it in the plant room as the first
+  pump set on the ring main instead of beside the press; system 2 and the
+  Classic add pump sets in parallel on one manifold with the accumulators,
+  and a standby set follows. Each branch gets its own isolation valves and
+  filter: with one shared oil system, a contamination event otherwise
+  reaches every press. Steam and cooling follow the same pattern; the
+  phased list for all three is in
+  [scale](../scale.md#utility-phasing-backbone-once-modules-with-the-presses).
 - **Cell layout (October 2026).** Each Duplex system is one operator's
   cell, as sketched in [duplex-cell-layout-sketch.png](duplex-cell-layout-sketch.png)
   (arrangement only, not to scale):
@@ -84,7 +98,10 @@ automated candidate). What it means:
   of cooling with extruders and hydraulics, against the ~400 kg/h steam
   generator and ~250 kW cooling system that the 2024 quote's exclusions
   describe for one Duplex. The proposal is a bank of two 500 kg/h boilers
-  and three 250 kW chillers, one module per press stage; the layout, the
+  and three 250 kW chillers, one module per press stage, in a boiler hall
+  and a chiller compound built for four modules each
+  ([scale](../scale.md#detached-utility-yard-parking-and-what-that-moves));
+  the layout, the
   operating cases and the open RFQ questions are in
   [steam and cooling](../steam-cooling.html), the electrical consequences in
   [scale](../scale.md) and the costs in the
@@ -100,7 +117,10 @@ automated candidate). What it means:
   Classic's price, weight, power, steam and cooling figures; and the
   central hydraulic supply (an option the flyer offers) for the whole
   fleet, extendable to ten more Classics, including whether the Classic
-  can run from it.
+  can run from it, whether the presses hold their pressure from it over
+  the ring-main lengths of the hall, the filtration and isolation each
+  branch needs, and whether the Single 2.1's aggregate can be its first
+  pump set.
 
 The Pheenix AD12 leaves the plan; it stays in the
 [vendor landscape](../suppliers/vendor-landscape.md) as the comparison if

docs/finance/phase1-construction-rfq.md

@@ -130,10 +130,19 @@ Simple industrial enclosures beside the main building.
 
 | Building | Area | Height |
 |---|---|---|
-| Boiler hall | 66 m² | 6.0 m |
+| Boiler hall, laid out for four 500 kg/h boiler modules | ~162 m² (18 × 9 m) | 6.0 m |
 | Biomass fuel store | 42 m² | 5.0 m |
-| Chiller room | 60 m² | 5.0 m |
-| Cooling tower pad (concrete pad only) | 10 m² | - |
+| Chiller compound: open to the sky, screened, four chiller pads (~4.0 × 2.6 m each) | ~135 m² (12.5 × 10.8 m) | screen ~2.5 m |
+| Cooling pump and heat-exchanger room | ~40 m² (8 × 5 m) | 4.0 m |
+
+The boiler hall and the chiller compound are built once for four modules
+each, and the plant goes in one module at a time as presses arrive
+([scale](../scale.md#detached-utility-yard-parking-and-what-that-moves)):
+price the floor, pads, plinths and wall openings for all four now. The
+sizes are estimates until the boiler and chiller vendors send footprints.
+Air-cooled chillers need open air, so the earlier "chiller room" is an open
+compound; the cooling tower pad of the water-cooled concept is deleted (a
+dry cooler, if bought, gets a pad sized with its quote).
 
 The 14 m flue stack comes with the boiler — excluded here. The boiler hall
 envelope should be non-combustible (mineral-wool panels or masonry), not
@@ -168,8 +177,8 @@ things follow:
 
 **On drainage.** 4,387 m² of pavement is about 46 % of the 9,567 m² plot,
 but the figure that matters for attenuation is the **total sealed area**:
-adding the main building (1,500 m²), utility yard (178 m²), guard house
-(12 m²) and parking canopies (271 m²) gives **6,348 m², or 66 % of the
+adding the main building (1,500 m²), utility yard (~379 m²), guard house
+(12 m²) and parking canopies (271 m²) gives **~6,549 m², or 68 % of the
 plot**. Quote the contractor that number, not the paving one.
 Runoff increases materially over the agricultural baseline, and
 stormwater attenuation — quite possibly a detention pond — may be required

docs/finance/total-investment.md

@@ -49,7 +49,8 @@ building, software and stamper prep lines, and the contingency on top).
 | Stamper prep re-priced: USD 250k for VSP, VSF and VSC against the 60k – 170k block above | +190k (low case) / +80k (high case) | +6.3M / +2.6M | Sibert's budget confirmation, email of 5 October 2026 ([galvanics and stamper prep](../equipment/galvanics.md)); itemised quotation to follow. Its time, spare parts, shipping and travel are extra and fall into the freight/installation and spares blocks above |
 | Press fleet changed (October 2026) to two Newbilt Duplex systems (two presses each, EX 50 main extruder and EX 35 colour extruder) plus one Newbilt Classic, replacing the two blocks above (930k – 1,290k): Duplex system 1 as the first block (350k – 370k; the quote's second-extruder option becomes the EX 35), system 2 ~230k – 300k (two presses at the quoted ~115k per press and extruder set as the yardstick, plus hydraulic unit and EX 35, estimate; no EX 35 price on file), the Classic ~290k – 460k (the AD12 band per press as a placeholder; no Newbilt price on file) | −60k (low case) / −160k (high case) | −2.0M / −5.3M | estimate, [pressing line](../equipment/pressing-line.md); the Newbilt re-quote replaces it. The utilities for five presses are re-sized in the row below |
 | Utilities re-sized for the five-press fleet (October 2026): boiler bank 2 × 500 kg/h, chiller bank 3 × 250 kW with plate heat exchanger and tanks, larger softener and loop treatment ([steam and cooling](../steam-cooling.html)) | +185k (low case) / +294k (high case) | +6.1M / +9.7M | estimate, [utilities CSV](utilities-investment.csv) re-based from 24.0M – 41.6M to 30.1M – 51.3M THB |
-| **Added so far** | **~605k – 905k** | **~19.9M – 29.9M** | about 12 to 15% on the full-vision subtotal |
+| Utility yard built for four boiler and four chiller modules (October 2026): yard ~379 m² against 178 m² ([scale](../scale.md#detached-utility-yard-parking-and-what-that-moves)) | 73k – 122k | 2.4M – 4.0M | estimate: the building rate above on the ~200 m² the yard grows by; the open chiller compound costs less than a building, so this is the cautious end. The valved branches and feeders for the empty positions are not priced yet |
+| **Added so far** | **~678k – 1,027k** | **~22.3M – 33.9M** | about 13 to 17% on the full-vision subtotal |
 
 ## Phased entry
 

docs/scale.md

@@ -92,20 +92,63 @@ fits; at the upper half, finished goods move to the phase 2 building.
 The massing model puts the boiler and chiller in a **detached utility yard**
 alongside the main building rather than inside it, which is what the boiler's
 own-room requirement in [facility security](facility-security.md) and biomass
-fuel delivery both push toward:
+fuel delivery both push toward. Its rooms are built once for **four boiler
+and four chiller modules** (decided October 2026), while the modules
+themselves arrive one press stage at a time
+([utility phasing](#utility-phasing-backbone-once-modules-with-the-presses)):
 
 | | Area | Height |
 |---|---|---|
-| Boiler hall | 66 m² | 6.0 m |
+| Boiler hall, four 500 kg/h module positions | ~162 m² (18 × 9 m) | 6.0 m |
 | Biomass fuel store | 42 m² | 5.0 m |
-| Chiller room | 60 m² | 5.0 m |
-| Cooling tower (outdoor pad) | 10 m² | 3.5 m |
+| Chiller compound, four 250 kW pads, open to the sky, screened | ~135 m² (12.5 × 10.8 m) | screen ~2.5 m |
+| Cooling pump and heat-exchanger room | ~40 m² (8 × 5 m) | 4.0 m |
 | Flue stack | - | 14 m |
 
-Boiler plus chiller at 126 m² lands inside the 100 to 150 m² the zone table
-allows, but moving them out of the main shed frees that floor for
-production, so either the main building shrinks by ~126 m² or the program
-grows into it. Decide which before the building is priced.
+All sizes are estimates until the boiler and chiller vendors send
+footprints:
+
+- **Boiler hall.** The fuel is still open, so the fired case sets the
+  size. The largest piece of a 500 kg/h biomass boiler is about
+  3.3 × 2.0 × 2.7 m (AIX DZL0.5 listing, checked October 2026). Four
+  3.5 m bays plus a 4 m bay for the feed tank, softener, feed pumps and
+  steam header make 18 m. A 2.5 m firing aisle, 1.5 m of fuel feed, the
+  boiler and 1.3 m behind it make 9 m. Dust collectors, fans and the stack
+  stand outside along the back wall. An electric bank (~3.0 × 1.5 m per
+  500 kg/h module, vendor listing) would need about half the hall.
+- **Chillers.** Air-cooled chillers need open air, so the earlier
+  "chiller room" becomes an open, screened compound plus a small enclosed
+  room for the heat exchanger, the cold tank and the pumps. A 250 kW
+  module rated at 40 °C is about the size of a Carrier 30RB 080 to 090:
+  2.4 to 3.6 × 2.24 × 2.28 m (Carrier's published dimensions, checked
+  October 2026). The pads are 4.0 × 2.6 m, in two rows of two, with
+  ~1.8 m to the screen and 2.0 m between the rows; the chosen unit's
+  clearance drawing governs. The cooling tower pad of the earlier
+  water-cooled concept is gone; a dry cooler, if bought, gets a pad sized
+  with its quote.
+- **What four positions carry.**
+  - Steam: four boilers give 2,000 kg/h, or 1,500 kg/h with one held in
+    reserve, enough for about eight presses at 180 kg/h. The five-press
+    fleet runs on B-1 and B-2, B-3 is the reserve, and B-4 is room for
+    about three more presses.
+  - Cooling: four chillers give 1,000 kW. The five presses (~652.5 kW)
+    already need three, so CH-4 is the reserve and there is no growth
+    position. Each further press adds ~130 kW with its extruder and
+    hydraulics; a sixth eats into the reserve, and seven is the limit with
+    none.
+  - Pads laid out for the next frame up (Carrier 30RB 120 to 150 class,
+    ~4.8 m long, roughly 350 kW at 40 °C, estimate) would let four
+    chillers carry about eight presses with one in reserve, matching the
+    boiler hall. That is a priced option for the chiller RFQ.
+
+The yard grows from 178 m² to ~379 m². The old 126 m² of boiler hall and
+chiller room fitted the 100 to 150 m² the zone table allows for them in the
+main building; the four-module rooms would not, which is one more reason the
+yard stays detached. Moving the plant out frees that zone-table floor for
+production, so either the main building shrinks by that much or the program
+grows into it. Decide which before the building is priced. The
+[Payap parts model](site-candidates.md#roof-pv-and-parking-canopies-part-and-draft-model-october-2026)
+draws the yard this way.
 
 Staff parking is roofed, in the front yard clear of the loading route:
 **10 car bays** (27.7 × 7.0 m canopy, 195 m²) and **~30 scooter spaces**
@@ -240,12 +283,13 @@ small against the connection, but its own feeder and meter.
   180 °C** (~510 to 610 kW thermal) at Newbilt's 150 to 180 kg/h per press.
   Proposed: **two 500 kg/h modules** (B-1 with the launch press and Duplex
   system 1, B-2 with system 2 and the Classic), 1,000 kg/h installed; a
-  third module for N+1 is an RFQ option
-  ([steam and cooling](steam-cooling.html)). The 2024 Newbilt quote's
+  third module for N+1 is an RFQ option, and the hall has a fourth position
+  for growth ([steam and cooling](steam-cooling.html)). The 2024 Newbilt quote's
   ~400 kg/h covers one Duplex system
 - Chiller bank: up to **~650 kW** of cooling; proposed **three 250 kW
   air-cooled modules** rated at 40 °C ambient, one per press stage, behind a
-  plate heat exchanger with warm and cold tanks (estimate)
+  plate heat exchanger with warm and cold tanks (estimate); the compound's
+  fourth pad takes the N+1 module
 - If biomass: **~350 to 400 t/yr** air-dry wood at ~1.0 to 1.1 million
   records a year, up to **~550 t/yr** at the start fleet's full ~1.5
   million (fuel follows records pressed, not presses installed); the 60 rai
@@ -253,6 +297,42 @@ small against the connection, but its own feeder and meter.
 - If LPG: a bulk tank on site sized with the boiler bank (the ~2.5 to 5 t
   first estimated was for one Duplex; no gas pipeline in the North)
 
+### Utility phasing: backbone once, modules with the presses
+
+The plant starts with one press. Everything that is cheap to oversize now
+and costly to change in a running plant is built for the five-press fleet
+at launch; the machines that make steam, cold water and oil pressure are
+bought in identical modules as presses arrive. Identical modules mean one
+set of spares and one service routine, and N+1 later is one more module,
+not a redesign.
+
+| Stage | Steam | Cooling | Hydraulics and air |
+|---|---|---|---|
+| Launch: Newbilt Single 2.1, one press | Boiler hall for four modules; T-1, WT-1, P-1; steam main and condensate return with a valved, blanked branch at every press position; **B-1** | Compound with four pads; TK-2 and TK-3 at full size; HX-1 frame for ~650 kW with plates for the launch duty; P-2 to P-4 on VFDs; supply and return mains for ~540 l/min with a valved branch per position; **CH-1** | Plant room at full size; hydraulic and air ring mains along the service trench, sized for the fleet, with a valved, capped tee per position; the Single 2.1's own unit in the plant room as the first pump set on the manifold; one compressor |
+| Duplex system 1 complete (second press, EX 35) | B-1 at 60 to 72 % load | CH-1 covers ~96 % of the hot-afternoon peak (~261 kW): the cold tank and cycle overlap carry the rest, or CH-2 comes forward if the hot season arrives first | Tap the ring main; the Single 2.1 unit is already sized for the second press |
+| Duplex system 2 | **B-2** | **CH-2** | A pump set added on the manifold; a second compressor if the air demand needs it |
+| Classic | Carried by B-1 and B-2 | **CH-3** | A pump set, if the Classic runs from the central plant (Newbilt re-quote) |
+| Options | **B-3** (N+1); **B-4** for about three more presses; ACC-1 accumulator; ECON-1 on a fired bank | **CH-4** (N+1); TC-1 dry cooler; pads for the ~350 kW frame | A standby pump set, or the Single 2.1 unit as standby |
+
+Also built at launch: one controller that sequences the boilers, chillers
+and pump sets lead and lag from the first module, and switchboard space and
+feeders for every later module. Beyond four modules, the ten optional
+Classics (~2.3 to 2.7 t/h, ~1.9 MW) are a utility phase of their own, on
+reserved ground with its own header connection.
+
+Two things to watch early:
+
+- A fired 500 kg/h boiler serving one press runs at ~30 to 36 % and cycles.
+  Newbilt's steam accumulator (ACC-1) steadies it; or the first module is
+  electric and biomass follows at the expansion ([biomass](biomass.md)),
+  at the price of the demand charge.
+- One large boiler or chiller bought at launch would run poorly at part
+  load, tie up capital in unused capacity and stop the plant when it fails.
+
+The hydraulic side and its re-quote questions are in
+[pressing line](equipment/pressing-line.md); the plant diagram and its
+operating cases in [steam and cooling](steam-cooling.html#phasing).
+
 ## People
 
 Rough mature-operation headcount (estimate): 4 to 6 press/finishing

docs/steam-cooling.html

@@ -131,24 +131,46 @@ td.low{color:var(--warn);font-weight:600}
       <tr><td>T-1</td><td>Feed tank / hotwell</td><td class="n">~1.5 m³, 90 to 95 °C</td><td>launch</td><td>estimate</td></tr>
       <tr><td>P-1</td><td>Feed pumps, duty/standby</td><td class="n">~1 m³/h, ~13 bar</td><td>launch</td><td>estimate</td></tr>
       <tr><td>B-1, B-2</td><td>Boiler modules, lead/lag</td><td class="n">2 × 500 kg/h, 10.5 bar</td><td>B-1 launch, B-2 with Duplex 2</td><td>proposal</td></tr>
-      <tr><td>B-3</td><td>Third module for N+1</td><td class="n">500 kg/h</td><td>option</td><td>RFQ option</td></tr>
+      <tr><td>B-3</td><td>Third module for N+1</td><td class="n">500 kg/h</td><td>option; position built at launch</td><td>RFQ option</td></tr>
+      <tr><td>B-4</td><td>Fourth position: pad, header branch, feeder</td><td class="n">500 kg/h</td><td>growth, ~3 more presses</td><td>position only</td></tr>
       <tr><td>ECON-1</td><td>Flue-gas economizer, fired boilers</td><td class="n">feed in 90 to 95 °C, out by vendor</td><td>with a fired bank</td><td>1st measure</td></tr>
       <tr><td>ACC-1</td><td>Steam accumulator</td><td class="n">by cycle overlap</td><td>option</td><td>Newbilt option</td></tr>
       <tr><td>HP-1</td><td>Heat-recovery heat pump</td><td class="n">feed tank to 90 to 95 °C</td><td>if it pays</td><td>3rd measure</td></tr>
       <tr><td>CH-1 to CH-3</td><td>Air-cooled chillers at 40 °C ambient</td><td class="n">3 × 250 kW</td><td>one per press stage</td><td>proposal</td></tr>
-      <tr><td>CH-4</td><td>Fourth module for N+1</td><td class="n">250 kW</td><td>option</td><td>RFQ option</td></tr>
-      <tr><td>HX-1</td><td>Plate heat exchanger</td><td class="n">~650 kW, ~2 K approach</td><td>launch, sized for 5</td><td>estimate</td></tr>
+      <tr><td>CH-4</td><td>Fourth module for N+1</td><td class="n">250 kW</td><td>option; pad built at launch</td><td>RFQ option</td></tr>
+      <tr><td>HX-1</td><td>Plate heat exchanger</td><td class="n">~650 kW, ~2 K approach</td><td>launch: frame for 5, plates as presses arrive</td><td>estimate</td></tr>
       <tr><td>TK-3, TK-2</td><td>Warm return / cold buffer tanks</td><td class="n">~5 m³ each</td><td>launch</td><td>estimate</td></tr>
       <tr><td>P-2, P-3, P-4</td><td>Transfer, VFD supply, primary pumps</td><td class="n">up to ~540 l/min</td><td>launch, staged</td><td>estimate</td></tr>
       <tr><td>TC-1</td><td>Dry cooler ahead of HX-1</td><td class="n">~650 to 750 kW reject</td><td>option</td><td>RFQ option</td></tr>
       <tr><td>GC</td><td>Galvanics cooling, separate</td><td class="n">12 to 20 °C, 10 L/min per PDPU</td><td>phase 5</td><td>open</td></tr>
     </table>
   </div>
+  <div class="card" id="phasing">
+    <h2>Phasing: backbone once, modules with the presses</h2>
+    <p>Everything that is cheap to oversize now and costly to change in a running plant is built for the five-press fleet at launch; boilers, chillers and hydraulic pump sets come in identical modules as presses arrive. One controller sequences them lead and lag from the first module.</p>
+    <table>
+      <tr><th>Stage</th><th>Steam</th><th>Cooling</th><th>Hydraulics, air</th></tr>
+      <tr><td>Launch (Single 2.1, one press)</td><td>hall for four modules; T-1, WT-1, P-1; mains with a valved, blanked branch per press position; <b>B-1</b></td><td>compound with four pads; TK-2, TK-3 full size; HX-1 frame for ~650 kW, plates for one press; P-2 to P-4 on VFDs; <b>CH-1</b></td><td>plant room full size; ring mains for the fleet, a capped tee per position; the Single 2.1 unit as the first pump set; one compressor</td></tr>
+      <tr><td>Duplex system 1</td><td>B-1 at 60 to 72 % load</td><td>CH-1 covers ~96 % of the peak: cold tank and cycle overlap, or CH-2 earlier</td><td>tap the ring main</td></tr>
+      <tr><td>Duplex system 2</td><td><b>B-2</b></td><td><b>CH-2</b></td><td>pump set on the manifold</td></tr>
+      <tr><td>Classic</td><td>B-1 and B-2</td><td><b>CH-3</b></td><td>pump set, if the Classic runs from the central plant</td></tr>
+      <tr><td>Options</td><td>B-3 (N+1), B-4 (growth), ACC-1, ECON-1</td><td>CH-4 (N+1), TC-1, pads for ~350 kW units</td><td>standby pump set</td></tr>
+    </table>
+    <h3>Rooms, four modules each (estimate)</h3>
+    <table>
+      <tr><th>Room</th><th>Size</th><th>Basis</th></tr>
+      <tr><td>Boiler hall</td><td class="n">~18 × 9 m, 6 m high</td><td>four 3.5 m bays plus 4 m for T-1, WT-1, P-1 and the header; fired case (500 kg/h biomass body ~3.3 × 2.0 m); electric needs about half</td></tr>
+      <tr><td>Chiller compound</td><td class="n">~12.5 × 10.8 m, open</td><td>four pads 4.0 × 2.6 m in two rows, screened; 250 kW at 40 °C is about a Carrier 30RB 080 to 090, 2.4 to 3.6 × 2.24 m</td></tr>
+      <tr><td>Pump and HX room</td><td class="n">~8 × 5 m</td><td>HX-1, TK-2, P-2 to P-4, drives</td></tr>
+    </table>
+    <p class="note">Four boilers carry about eight presses with one in reserve. Four 250 kW chillers carry the five presses with CH-4 in reserve and leave no growth position, unless the pads take the larger frame (scale.md).</p>
+  </div>
   <div class="card">
     <h2>Open for the RFQs</h2>
     <h3>Newbilt (re-quote)</h3>
     <ul>
       <li>Classic: steam, cooling, power, weight; can it run from the central hydraulic plant?</li>
+      <li>Central hydraulics: pressure at the presses over the ring-main lengths, filtration and isolation per branch, and whether the Single 2.1 unit can be the first central pump set.</li>
       <li>Press return temperature over the cycle: 53 l/min at ~60 °C out of 20 to 25 °C is ~140 kW, more than the stated 125 kW peak. The real profile sizes HP-1, HX-1 and TC-1.</li>
       <li>Is the accumulator needed with a modular boiler bank, and how big?</li>
       <li>Condensate: the 2024 offer has one steam/water outlet valve and a steam trap per mould. How much cooling water reaches the trap per cycle, and can that condensate go back to boiler feed?</li>
@@ -159,11 +181,13 @@ td.low{color:var(--warn);font-weight:600}
       <li>Fuel: electric, biomass or LPG (sustainability.md, biomass.md); the electric bank draws ~520 to 625 kW.</li>
       <li>Economizer on a fired bank: outlet feed and stack temperature, corrosion limit, pressure drop; rice husk ash is high in silica and abrasive, so fouling, cleaning, wear protection and a bypass.</li>
       <li>Blowdown cooling to the effluent limit; boiler registration and licensed operator (facility-security.md).</li>
+      <li>Footprint per module with fuel feed, dust collector and fan, against the ~18 × 9 m hall laid out for four modules.</li>
     </ul>
     <h3>Chillers (Trane, Carrier, Daikin Applied, Hitachi)</h3>
     <ul>
       <li>3 × 250 kW against 3 × 350 kW (N+1), rated at 40 °C ambient; part-load efficiency.</li>
       <li>Plate heat exchanger and tanks in scope; dry cooler TC-1 as a priced option.</li>
+      <li>Clearance drawing for four units in two rows of two; pads for the ~350 kW frame as a priced option (four would then carry about eight presses with one in reserve).</li>
     </ul>
     <h3>Site</h3>
     <ul>
@@ -309,26 +333,26 @@ const D={
  WT1:{t:'WT-1 · Boiler feedwater treatment',w:'A duplex softener (one regenerates while the other works) and chemical dosing (oxygen scavenger, pH) protect the boilers. RO only if the analysis demands low TDS; it is an option row, not the baseline.',f:['Duplex softener 120k to 300k THB, sized up for the five-press fleet (utilities CSV, market estimate)','RO skid 200k to 500k THB, option only (utilities CSV)'],q:['Softener alone or softener plus RO, after the water analysis']},
  T1:{t:'T-1 · Feed tank and hotwell',w:'Collects the condensate returning from the presses and the treated make-up, warmed by HP-1, and holds the feedwater at 90 to 95 °C so little oxygen stays dissolved. The boiler then only does the final lift to 180 °C.',f:['Feedwater at 90 to 95 °C and the boiler only doing the final lift (sustainability.md)','Heat recovery plus condensate return save roughly 10 to 15 % of steam energy (sustainability.md)','~1.5 m³, about 1.5 h of feed at full output (estimate); level LT logged','Condensate leaves each trap near saturation (~180 °C at the press) and flashes to about 100 °C in the atmospheric return (estimate); the flash steam is heat that could be recovered','Steam and cooling water share the mould channels, with one outlet valve and steam trap per mould (Newbilt offer 240620-04): the condensate is only as clean as the cooling loop, so AT conductivity on the return diverts off-spec condensate to the warm tank (proposal)','Order of heat recovery for the feedwater: flue-gas economizer, condensate return, then HP-1 (sustainability.md)'],q:['Atmospheric hotwell or pressurised deaerator: boiler vendor\'s call at this size']},
  P1:{t:'P-1 · Boiler feed pumps',w:'Duty and standby multistage pumps feed every boiler module through one manifold, so a pump failure never stops steam.',f:['~1 m³/h each against ~13 bar (estimate, above the 10.5 bar boiler pressure)'],q:['Supplied with the boiler bank or separately']},
- boiler:{t:'B-1 and B-2 · Boiler modules, 500 kg/h each',w:'Two modules run lead and lag at ~10.5 bar so the presses see 9.5 to 10.5 bar after the line. B-1 comes with the launch press and covers all of Duplex system 1 (300 to 360 kg/h); B-2 comes with Duplex system 2 and also carries the Classic. Fuel is open: electric, biomass or LPG.',f:['Newbilt: 150 to 180 kg/h per press, Duplex up to 360 kg/h, min. 10 bar, 9.5 to 10.5 bar operating (site requirements 3.2.3, vendor)','Five presses: 750 to 900 kg/h, against 1,000 kg/h installed (111 to 133 %)','The 2024 Newbilt quote excludes a ~400 kg/h steam generator: one Duplex system (pressing-line.md)','Electric alternative ~350 kW input per module, 520 to 625 kW at full demand (0.68 kWh/kg at 98 %, estimate)','With one module down, 500 kg/h runs about three presses','Boiler bank 4.5M to 7M THB installed (utilities CSV, estimate)'],q:['2 × 500 kg/h against 3 × 500 kg/h (B-3) and a single 1 t/h boiler: price, footprint, the cost of a lost shift','Fuel decision (biomass.md, sustainability.md)','Service response from Chiang Mai: the candidates are Bangkok-based']},
+ boiler:{t:'B-1 and B-2 · Boiler modules, 500 kg/h each',w:'Two modules run lead and lag at ~10.5 bar so the presses see 9.5 to 10.5 bar after the line. B-1 comes with the launch press and covers all of Duplex system 1 (300 to 360 kg/h); B-2 comes with Duplex system 2 and also carries the Classic. Fuel is open: electric, biomass or LPG.',f:['Newbilt: 150 to 180 kg/h per press, Duplex up to 360 kg/h, min. 10 bar, 9.5 to 10.5 bar operating (site requirements 3.2.3, vendor)','Five presses: 750 to 900 kg/h, against 1,000 kg/h installed (111 to 133 %)','The 2024 Newbilt quote excludes a ~400 kg/h steam generator: one Duplex system (pressing-line.md)','Electric alternative ~350 kW input per module, 520 to 625 kW at full demand (0.68 kWh/kg at 98 %, estimate)','With one module down, 500 kg/h runs about three presses','Boiler bank 4.5M to 7M THB installed (utilities CSV, estimate)','Boiler hall laid out for four modules (~18 × 9 m, estimate): B-3 and B-4 drop onto waiting pads and header branches (scale.md)'],q:['2 × 500 kg/h against 3 × 500 kg/h (B-3) and a single 1 t/h boiler: price, footprint, the cost of a lost shift','Footprint per module with fuel feed, dust collector and fan, against the four-module hall','Fuel decision (biomass.md, sustainability.md)','Service response from Chiang Mai: the candidates are Bangkok-based']},
  ECON1:{t:'ECON-1 · Flue-gas economizer (fired boilers)',w:'On a fired boiler bank (biomass such as rice husk, or LPG) the flue gas leaves hot. An economizer between the feed pumps and the boilers recovers part of that heat into the feedwater: the first of the three heat-recovery measures to investigate. An electric boiler has no flue gas and runs on the bypass.',f:['Feedwater in at 90 to 95 °C from T-1 (sustainability.md)','Outlet feed and stack temperatures are vendor figures: how far the gas can be cooled depends on its temperature and the corrosion limit','The gas-fired package row in the utilities CSV already includes an economizer; the biomass row does not yet'],q:['Outlet feed and stack temperature, pressure drop, corrosion limit','Rice husk ash is high in silica and abrasive: fouling, cleaning, wear protection and a bypass']},
- B3:{t:'B-3 · Third boiler module (option)',w:'A third 500 kg/h module keeps all five presses running with any one module out. Without it a boiler fault costs about two presses until it is fixed.',f:['3 × 500 kg/h = 1,500 kg/h, full demand with one module out'],q:['Priced as an option in the boiler RFQ; decided against measured cycle overlap and the cost of a lost shift']},
- BD1:{t:'BD-1 · Blowdown vessel and safety-valve discharge',w:'Boiler blowdown and drains flash in a vessel; the flash steam vents outside, the water is cooled before it reaches the drain. Safety valves discharge to a safe place outside the boiler hall.',f:['Boiler in its own room, Department of Industrial Works rules, licensed boiler operator (facility-security.md)','Detached boiler hall of ~66 m² with a 14 m flue (scale.md)'],q:['Drain temperature and quality against the industrial effluent limit']},
+ B3:{t:'B-3 · Third boiler module (option)',w:'A third 500 kg/h module keeps all five presses running with any one module out. Without it a boiler fault costs about two presses until it is fixed.',f:['3 × 500 kg/h = 1,500 kg/h, full demand with one module out','Its pad, header branch and feeder space are built at launch; a fourth position (B-4) is kept for about three more presses'],q:['Priced as an option in the boiler RFQ; decided against measured cycle overlap and the cost of a lost shift']},
+ BD1:{t:'BD-1 · Blowdown vessel and safety-valve discharge',w:'Boiler blowdown and drains flash in a vessel; the flash steam vents outside, the water is cooled before it reaches the drain. Safety valves discharge to a safe place outside the boiler hall.',f:['Boiler in its own room, Department of Industrial Works rules, licensed boiler operator (facility-security.md)','Detached boiler hall of ~162 m² (18 × 9 m) laid out for four modules, with a 14 m flue (scale.md, estimate)'],q:['Drain temperature and quality against the industrial effluent limit']},
  SEP1:{t:'SEP-1 · Separator and steam metering',w:'Removes entrained water so the moulds get dry steam. FT-101 and PT-101 log steam flow and pressure: steam per record pressed becomes a plant KPI next to the traceability record.',f:['Telegraf/MQTT acquisition into the plant data platform (digital-factory.md)','Saturated steam: Newbilt states 10 bar and 180 °C; 180 °C is saturation at 10 bar absolute, at 10 bar gauge it would be ~184 °C (to confirm which Newbilt means)'],q:['Meter type and turndown for 150 to 1,000 kg/h']},
  ACC1:{t:'ACC-1 · Steam accumulator (option)',w:'Each press draws steam in bursts during its steam phase. An accumulator rides those peaks so the boilers see a steadier load. It does not add capacity: the bank must still cover the hourly demand.',f:['Already a Newbilt option (sustainability.md)'],q:['Needed at all with two modules? Size from the presses\' cycle overlap (Newbilt re-quote)']},
  HP1:{t:'HP-1 · Heat-recovery heat pump',w:'Third of the three heat-recovery measures for the feedwater, after the flue-gas economizer and condensate return. A water-to-water heat pump takes heat from the warm press return before it reaches the chillers and heats the feed tank. It runs only where the tank still needs heat, the press return has enough of it, and the combined saving on boiler fuel and chiller power beats its own electricity. With most condensate returned the remaining tank load is small, so HP-1 may not pay.',f:['Press return ~60 °C, feedwater 90 to 95 °C, 10 to 15 % steam saving with condensate return (sustainability.md)','Heating all make-up from 20 to 90 °C at full output is only ~70 kW thermal, small against ~650 kW of cooling (estimate)','Source side in up to ~60 °C from the return header, out set by the heat pump vendor; feed loop back to T-1 at up to 95 °C (sustainability.md)','About 15 % of the condensate flashes to steam when it drops from ~180 °C to atmospheric pressure (estimate); with the rest returned the feed tank needs only a fraction of the ~70 kW'],q:['Real return temperature profile from Newbilt: it sets the heat pump\'s lift and COP','Second use for recovered heat: label oven, HVAC reheat (sustainability.md)']},
  press:{t:'Duplex presses · HRP 12 (Newbilt)',w:'Each press takes steam from the top of the header through an isolation valve, strainer and control valve, with its own pressure transmitter, and returns condensate through its own trap. Cooling water comes from the 10 bar supply header and drains open to the warm tank; flow and return temperature on each branch give that press\'s cooling load.',f:['Steam 150 to 180 kg/h, min. 10 bar, G 1 connection (site requirements 3.2.3, vendor)','Cooling water up to 100 l/min, ~53 l/min used, in 20 to 25 °C at 10 bar, out max. 2 bar open, average outlet ~60 °C, up to 125 kW (site requirements 3.2.2, vendor)','Water quality 7 to 8 °dH, pH 7 to 9, particles ≤ 200 µm, ≤ 500 µS/cm (site requirements 3.1.2, vendor)'],q:['53 l/min warming from 20 to 25 °C to ~60 °C is ~140 kW, above the stated 125 kW peak: ask for the measured return profile over a cycle']},
  classic:{t:'Classic · automatic press (Newbilt)',w:'Fully automatic, with its own extruder. Newbilt has published no steam, cooling or power figures, so it is drawn and counted as one HRP 12 press plus one extruder.',f:['Toolex Alpha leaflet (the Classic\'s base): 1.2 kg steam and 15 l cooling water per cycle, ~144 kg/h of steam at 2 cycles a minute (fleet calculator, cross-check)','Monitors steam temperature, cooling water temperature and flow; cooling by time or delivered volume (2024 flyer)'],q:['Steam, cooling, power and weight for the re-quote; whether it runs from the central hydraulic plant']},
  EX1:{t:'EX · Extruder cooling',w:'Every extruder needs a little cooling water at the same 20 to 25 °C. The EX 35 and the Classic\'s built-in extruder are counted like the EX 50 until Newbilt states theirs.',f:['~4 l/min, 2 to 3 kW, in 20 to 25 °C at 5 to 10 bar, outlet nearly without pressure (site requirements 3.3.3, vendor)','Five extruders at the start fleet: ~20 l/min, ~15 kW','Outlet ~30 to 35 °C: 2 to 3 kW at 4 l/min is a 7 to 11 K rise (estimate)'],q:['EX 35 and Classic extruder cooling figures']},
- HY1:{t:'HY · Hydraulic oil cooler (central plant)',w:'The central hydraulic plant feeding all presses rejects its heat through one oil cooler on the same loop.',f:['Per aggregate ~8 l/min, ΔT max ~10 °C, up to 5 kW (site requirements 3.4.2, vendor); 2.5 kW per press in the calculator','~12.5 kW and ~20 l/min for five presses (estimate)','Outlet at most ~35 °C: supply 20 to 25 °C plus the maximum ~10 °C rise (site requirements 3.4.2)'],q:['Central plant cooler duty from Newbilt']},
+ HY1:{t:'HY · Hydraulic oil cooler (central plant)',w:'The central hydraulic plant feeding all presses rejects its heat through one oil cooler on the same loop.',f:['Per aggregate ~8 l/min, ΔT max ~10 °C, up to 5 kW (site requirements 3.4.2, vendor); 2.5 kW per press in the calculator','~12.5 kW and ~20 l/min for five presses (estimate)','Pump sets in parallel on one manifold, added as presses arrive; the Single 2.1 unit is the first (pressing-line.md, proposal)','Outlet at most ~35 °C: supply 20 to 25 °C plus the maximum ~10 °C rise (site requirements 3.4.2)'],q:['Central plant cooler duty from Newbilt']},
  TK3:{t:'TK-3 · Warm return tank',w:'Newbilt\'s press outlets run open at max. 2 bar with ideally no back pressure, so the returns drain into a vented tank instead of a pressurised header. Transfer pumps take it on through heat recovery and the heat exchanger.',f:['Outlet max. 2 bar, open system (site requirements 3.2.2, vendor)','~5 m³ (estimate); level and TT-302 logged','Mixed temperature below the ~60 °C press outlet, because the extruder and oil cooler returns are cooler; set it from the measured return profile Newbilt is asked for'],q:['Height of the return header above the tank, from the hall layout']},
  P2:{t:'P-2 · Transfer pumps',w:'Duty and standby pumps move the warm return at a steady flow through HP-1, the optional dry cooler and HX-1 into the cold tank, so neither the heat exchanger nor the chillers see the presses\' flow swings.',f:['Up to ~540 l/min for five presses (estimate)'],q:[]},
  TC1:{t:'TC-1 · Dry cooler (option)',w:'With returns near 40 to 60 °C, outside air removes much of the heat for most of the year before the chillers trim the rest. A hybrid of tower or dry cooler plus trim chiller is the efficiency-optimal design; the chiller is the safe choice for the hot-season wet bulb.',f:['Utilities CSV: tower + HX alternative 2M to 3.5M THB at ~650 to 750 kW reject, not in the baseline'],q:['Priced as an option with the chillers; savings against Chiang Mai weather']},
- HX1:{t:'HX-1 · Plate heat exchanger',w:'Separates the open process side (air and dust get in at the warm tank) from the closed, clean chiller loop, so the chiller evaporators never see dirty, oxygenated water.',f:['~650 kW at ~2 K approach (estimate)'],q:['Single or two plates for maintenance without stopping production']},
+ HX1:{t:'HX-1 · Plate heat exchanger',w:'Separates the open process side (air and dust get in at the warm tank) from the closed, clean chiller loop, so the chiller evaporators never see dirty, oxygenated water.',f:['~650 kW at ~2 K approach (estimate)','Frame bought for the full duty, plates added as presses arrive (proposal)'],q:['Single or two plates for maintenance without stopping production']},
  TK2:{t:'TK-2 · Cold buffer tank',w:'Holds water at 20 to 25 °C between the steady chiller side and the bursty presses: overlapping cooling phases draw from the tank, and the chillers do not short-cycle.',f:['Newbilt inlet 20 to 25 °C (site requirements 3.2.2, vendor)','~5 m³ (estimate)'],q:[]},
  P3:{t:'P-3 · Supply pumps',w:'Variable-speed duty and standby pumps hold ~10 bar at the press inlets however many presses run. PT-301, TT-301 and FT-301 log the supply.',f:['Press inlet 10 bar, extruders and oil cooler 5 to 10 bar (site requirements, vendor)','Up to ~540 l/min for five presses (estimate)'],q:[]},
  P4:{t:'P-4 · Primary pumps',w:'Duty and standby pumps circulate the closed chiller loop between the chiller bank and HX-1.',f:['Sized with the chiller bank (estimate)'],q:[]},
- chiller:{t:'CH-1 to CH-3 · Air-cooled chillers, 250 kW each',w:'Three modules phased with the presses: CH-1 with the launch press and Duplex system 1, CH-2 with system 2, CH-3 with the Classic. Rated at 40 °C ambient, because Chiang Mai\'s April afternoons are when all presses cool hardest.',f:['Five presses up to 652.5 kW (625 presses, 15 extruders, 12.5 hydraulics) against 750 kW installed (115 %)','Electrical input ~80 to 125 kW per 250 kW: ~210 to 325 kW at the peak (scale.md, estimate)','One 250 kW module matches the ~250 kW cooling system the 2024 quote excludes for one Duplex (pressing-line.md)','Chiller bank 6.5M to 10.5M THB installed with HX, tanks and pumps (utilities CSV, estimate)','Chiller loop to HX-1 ~18 to 23 °C for a 20 to 25 °C process supply at a ~2 K approach (estimate); its return temperature comes with the chiller selection'],q:['3 × 250 kW against 3 × 350 kW for N+1; part-load efficiency; derating at 40 °C']},
- CH4:{t:'CH-4 · Fourth chiller (option)',w:'Without it one chiller out leaves 500 kW, ~77 % of the peak: the cold tank and the presses\' cycle diversity carry most hours, not the hottest afternoons. A fourth module, or 3 × 350 kW, makes it N+1.',f:['4 × 250 kW = 1,000 kW'],q:['Priced as an option']},
+ chiller:{t:'CH-1 to CH-3 · Air-cooled chillers, 250 kW each',w:'Three modules phased with the presses: CH-1 with the launch press and Duplex system 1, CH-2 with system 2, CH-3 with the Classic. Rated at 40 °C ambient, because Chiang Mai\'s April afternoons are when all presses cool hardest.',f:['Five presses up to 652.5 kW (625 presses, 15 extruders, 12.5 hydraulics) against 750 kW installed (115 %)','Electrical input ~80 to 125 kW per 250 kW: ~210 to 325 kW at the peak (scale.md, estimate)','One 250 kW module matches the ~250 kW cooling system the 2024 quote excludes for one Duplex (pressing-line.md)','Open, screened compound with four pads (~12.5 × 10.8 m) next to a ~40 m² pump and HX room (scale.md, estimate)','Chiller bank 6.5M to 10.5M THB installed with HX, tanks and pumps (utilities CSV, estimate)','Chiller loop to HX-1 ~18 to 23 °C for a 20 to 25 °C process supply at a ~2 K approach (estimate); its return temperature comes with the chiller selection'],q:['3 × 250 kW against 3 × 350 kW for N+1; part-load efficiency; derating at 40 °C']},
+ CH4:{t:'CH-4 · Fourth chiller (option)',w:'Without it one chiller out leaves 500 kW, ~77 % of the peak: the cold tank and the presses\' cycle diversity carry most hours, not the hottest afternoons. A fourth module, or 3 × 350 kW, makes it N+1. Its pad is built at launch.',f:['4 × 250 kW = 1,000 kW','The five presses already use three modules, so CH-4 is the reserve and the compound has no growth position unless the pads take the ~350 kW frame (scale.md)'],q:['Priced as an option']},
  AS1:{t:'AS-1 · Air and dirt separator, expansion vessel',w:'Keeps the closed chiller loop pressurised and free of air and debris.',f:[],q:[]},
  WT2:{t:'WT-2 · Loop treatment',w:'The open return tank picks up air and dust, so side-stream filtration and dosing keep the process water inside Newbilt\'s limits. Make-up comes softened from WT-1.',f:['7 to 8 °dH, pH 7 to 9, particles ≤ 200 µm, ≤ 500 µS/cm, chlorine ≤ 20 mg/l (site requirements 3.1.2, vendor)','200k to 500k THB (utilities CSV, estimate)'],q:[]},
  GC1:{t:'GC · Galvanics cooling (separate circuit)',w:'The Pheenix PDPU wants colder water than the presses and very little of it, so it does not share the press loop: either a small dedicated chiller or a separately controlled branch through its own heat exchanger. Phase 5.',f:['PDPU: 12 to 20 °C at 5 bar, 10 L/min through its titanium coil (galvanics.md, vendor)','OMS thinks passive cooling may do; open whether that holds above 30 °C ambient (galvanics.md)'],q:['Galvanics vendor\'s final requirement; HVAC for the clean room is separate']},