General Technical Spacifications for Keban HEPP Rehabilitation Works

KEBAN REHABILITATION CONSULTANT

ELECTROWATT-EKONO AG Hardturmstrasse 161, P.O. Box CH-8037 Zurich / Switzerland Tel. +41 76 356 22 79 Fax +41 44 355 55 64 E-mail [email protected]

ELECTRICITE DE FRANCE David Fauriel FR-73373 Le Bourget-du-Lac / France Tel. +33 4 79 60 60 73 Fax +33 4 79 60 62 40 E-mail [email protected]

DOLSAR ENGINEERING LIMITED Kennedy Caddesi 43, Kavaklidere TR-6660 Ankara / Turkey Tel. +90 312 417 90 00 Fax +90 312 418 10 66 E-mail [email protected]

EÜAŞ KEBAN HPP Rehabilitation Works

April 28, 2008Rev 001

General Technical Specification (GTS)

Keban HPP General Technical Specification










Keban Rehabilitation

Structure of Tender Documents

Volume 0 Invitation and Instructions to Bidders

Volume 1 Administration Specifications

Volume 2 Technical Specifications

− Section 1 General Technical Specifications (GTS)

− Section 2 Common Particular Technical Specifications with time schedule (CPTS)

− Section 3 Particular Technical Specifications ( PTS); P1-PTS, P2-PTS, P3-PTS, P4-PTS and P5-PTS

− Section 4 Data Sheets (DS);

P1-DS, P2-DS, P3-DS, P4-DS and P5-DS

− Section 5 Drawings (List of the drawings is provided in the CPTS)

− Section 6 Work Programme

Volume 3 Contract

Volume 4 Standard Forms

− Section 1 Price Schedule (PS);

P1-PS, P2-PS, P3-PS, P4-PS and P5-PS

− Section 2 Other Forms stipulated in the Adm. Spec. Article 6.1

(From Appendix 1 to Appendix 27)


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Contents

1 GENERAL REQUIREMENTS 1

1.1 General 1

1.2 Scope of Work 1

1.3 Standards 1 1.3.1 Certification of Contractor 2 1.3.2 Standards for General Application 2 1.3.3 Basic Design, Manufacturing and Testing Standards 3 1.3.4 Material Standards 4

1.4 Units of Measurements 4

1.5 Works Identification System 4

1.6 Construction Program 5

2 TECHNICAL DOCUMENTS 6

2.1 General 6

2.2 Drawings 8 2.2.1 Loading Drawings 8 2.2.2 Foundation Drawings 8 2.2.3 Arrangement and Layout Drawings 8 2.2.4 Outline Drawings 9 2.2.5 Design Drawings 9 2.2.6 Installation Drawings 10

2.3 Diagrams 10 2.3.1 Single-Line Diagrams 10 2.3.2 Circuit Diagrams 10 2.3.3 Block Diagrams 11 2.3.4 Logic Diagrams 11 2.3.5 Terminal Diagrams 12 2.3.6 Protection Coordination Diagrams 12

2.4 Material Specification 12

2.5 Lists and Schedules 13 2.5.1 General 13 2.5.2 Consumer (Motor) Data Schedule (MDS) 13 2.5.3 Motor Starter Lists 14 2.5.4 Feeder Data Schedule (FDS) 14 2.5.5 Cable Data Sheet (CDS) and Cable Laying Schedule (CLS) 15 2.5.6 Data Point List 15 2.5.7 Setting List 16 2.5.8 Alarm and Tripping List 16 2.5.9 Workshop Test Schedules 16 2.5.10 Site Test Schedules 17 2.5.11 List of Tools and Appliances 17 2.5.12 Spare Part Lists 17


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2.5.13 List of EDS Identification Numbers 17

2.6 Calculations 17

2.7 Installation and Commissioning Procedures 18 2.7.1 Installation Procedures 18 2.7.2 Pre-Commissioning Procedures 18 2.7.3 Commissioning Procedures 18

2.8 Operation and Maintenance Manuals 18 2.8.1 Contents 18 2.8.2 Format and Compilation 20 2.8.3 Revisions and Supplements 20

2.9 Progress Reports during Design and Manufacturing 21

2.10 Test Reports During Manufacturing 22

2.11 Progress Reports During Installation at Site 22

2.12 Test report during installation on site 23

2.13 Commissioning Report 23

3 SPARE PARTS AND TOOLS 24

3.1 Spare Parts 24 3.1.1 Specified Spare Parts 24 3.1.2 Recommended Spare Parts 24

3.2 Tools and Appliances 24

4 DESIGN AND MANUFACTURE 26

4.1 Design and Construction Requirements 26

4.2 Allowable Stress 27 4.2.1 General 27 4.2.2 Custom designed equipment such as turbine, generator, main inlet valve etc. 27 4.2.3 Standard equipment 28 4.2.4 Hoisting equipment and steel structures 28

4.3 Design Criteria 28 4.3.1 Seismic Loads 29 4.3.2 Wind Load 29

4.4 Standardization of Works 29

4.5 Noise 30

4.6 Identification Plates and Labels 30 4.6.1 General 30 4.6.2 Manufacturer's Nameplates 30 4.6.3 Identification Plates 31 4.6.4 Instruction Plates 31 4.6.5 Warning Plates 31 4.6.6 Labels for Conduits, etc. 31


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4.6.7 Labels for Cables 31 4.6.8 Rating Plates 31 4.6.9 Single-Line Diagrams 31 4.6.10 Key System for Electric Boards 32

4.7 Corrosion Protection 32 4.7.1 Painting 32 4.7.1.1 Scope of Work 32 4.7.1.2 Painting Materials 32 4.7.1.3 Workmanship 33 4.7.1.4 Painting Systems 36 4.7.1.5 Color Code 37 4.7.1.6 Repair of Primer and Finish Coats 37 4.7.2 Galvanizing 38 4.7.3 Finished Surfaces 39 4.7.4 Unfinished Surfaces 39 4.7.5 Protection of Machined Surfaces 39 4.7.6 Rounding, Chamfers, Edges 39

4.8 Welding and Heat Treatment 39 4.8.1 General 39 4.8.2 Welding 40 4.8.3 Welding Qualifications 42 4.8.4 Welding Work 42 4.8.5 Heat Treatment 44 4.8.6 Quality and Procedure Control 44 4.8.7 Defects and Repairs 45

5 MECHANICAL WORKS, METAL AND STEEL STRUCTURES 46

5.1 General 46

5.2 Bolts, Screws, Nuts, etc. 46

5.3 Seals 47

5.4 Protection Guards 47

5.5 Drives and Gears 47

5.6 Lubrication, Lubricants, Fuel 47

5.7 Piping, Fittings, Valves and Gates 48 5.7.1 General 48 5.7.2 Water Piping and Fittings 49 5.7.3 Valves, Gates 49 5.7.4 Oil Piping 50 5.7.5 Pipe Supports and Hangers 50

5.8 Mechanical Instruments 51

5.9 Pressure Oil Systems 51 5.9.1 Hydraulic Pressure Units 51 5.9.2 Manufacturing and Tests 51 5.9.3 Maintenance 52


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5.9.4 Safety 52 5.9.5 Oils 52 5.9.6 Oil Tests 53

5.10 Compressed Air Systems 53

5.11 Pumps 54

5.12 Lifting Equipment 56 5.12.1 Design and Calculation Standards 56 5.12.2 Material Standards 57 5.12.3 Admissible stresses 57 5.12.4 General Design Particulars 58

5.13 Steel Structures 58

5.14 Hydromechanical Equipment- Design and Manufacture 59 5.14.1 Selection of Equipment 59 5.14.2 Design Loads 60 5.14.3 Allowable Stresses 60 5.14.4 Corrosion Allowance 60 5.14.5 Skin Plates 60

5.15 Gate Hoists 61 5.15.1 Operating Load 61 5.15.2 Allowable Stresses 61 5.15.3 Operating Speed 61 5.15.4 Motor Output 61 5.15.5 Diameter of Wire Drum and Sheave 62 5.15.6 Oil Hydraulics 62 5.15.7 Leakage of Gates 62

5.16 Cranes and Lifting Equipment for Gates 63 5.16.1 Design Loads 63 5.16.2 Allowable Stresses 63 5.16.3 Operating Classification 63 5.16.4 Wire Ropes 63

5.17 Quality of Materials and Equipment 64 5.17.1 Material Preparation 64 5.17.1.1 Material Identification 64 5.17.1.2 Cutting and Edge Preparation 64 5.17.1.3 Forming of Curved Plates 64 5.17.1.4 Straightening 65 5.17.2 Spacing of Seams and Splices 65 5.17.2.1 Stiffeners 65 5.17.2.2 Splices 65 5.17.2.3 Beams 65 5.17.3 Laying-out, Alignment and Fit-up 65 5.17.3.1 Laying-out 65 5.17.3.2 Alignment and Fit-up for Welding and Tack Welding 66 5.17.3.3 Temporary Attachment Welds 66 5.17.3.4 Cope Holes 66 5.17.4 Temporary and Non-structural Attachments and Cut-outs 66


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5.17.4.1 Welding 66 5.17.4.2 Removal 67 5.17.4.3 Temporary Cut-Outs 67 5.17.5 Finishing of Surfaces 67 5.17.6 Repair and Remedial Procedures 67 5.17.6.1 Repair Welding 67 5.17.6.2 Straightening of Distorted Members 68 5.17.7 Temporary Fabrication Aids 68 5.17.7.1 Temporary Bracing and Supports 68 5.17.7.2 Rectification of Surface Defects and Edge Laminations 69 5.17.7.3 Erection Loads and Stability 69

6 ELECTRICAL SYSTEMS 70

6.1 General 70

6.2 Standards 70

6.3 Operation Voltage and Characteristic 71 6.3.1 Low Voltage AC Power System 71 6.3.2 Direct Current and Uninterrupted Power Supply UPS 71 6.3.2.1 220V DC System 71 6.3.2.2 110V DC System 71 6.3.2.3 48V DC System 71 6.3.2.4 400/230V Uninterrupted Power Supply System 72

6.4 Electric Motors 72 6.4.1 General 72 6.4.2 Motor Voltages and Power Ratings 72 6.4.3 Rating 73 6.4.4 Starting 73 6.4.5 Windings and Insulation Class 74 6.4.6 Ventilation and Type of Enclosure 74 6.4.7 Bearings 74 6.4.8 Shafts and Couplings 75 6.4.9 Brushgear and Commutators 75 6.4.10 Terminal Boxes and Grounding 75 6.4.11 Measuring and Monitoring 76 6.4.12 Vibrations 76 6.4.13 Tests 76

6.5 MV and LV Switchgear, Cubicles and Panels 77 6.5.1 General Design and Construction Features 77 6.5.2 Switchgear/Motor Control Center (MCC) Feeders and Starters 79 6.5.2.1 Circuit Breakers 80 6.5.2.2 Contactors 81 6.5.2.3 Fuses 81 6.5.2.4 Load Break Switches 81 6.5.3 Switchgear/MCC Control 82 6.5.4 Small Wiring 83 6.5.5 Marking of Equipment and Wiring 84 6.5.6 Color Coding of Electrical Connections 84


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6.6 Instrument Transformers 86

6.7 Protection Devices 86

6.8 Auxiliary Equipment 87 6.8.1 Auxiliary Switches 87 6.8.2 Control Switches 87 6.8.3 Anti-Condensation Heaters 88 6.8.4 Electrical Connections 88

6.9 Cables and Cable Laying 88 6.9.1 General 88 6.9.2 Standards 89 6.9.3 Insulation Materials 89 6.9.4 Rated Voltages and Test Voltages 89 6.9.5 Voltage Drops 90 6.9.6 Power Cables 90 6.9.7 Instrumentation, Control and Communication Cables 90 6.9.8 Cable Laying 91 6.9.8.1 General 91 6.9.8.2 Partition and Sealing 93 6.9.8.3 Cable Arrangement 93 6.9.9 Cable Termination 94 6.9.10 Tests 94 6.9.10.1 Workshop tests 94 6.9.10.2 Site tests 94

6.10 Equipment Grounding 95

6.11 Explosion-Proof Works 95 6.11.1 General 95 6.11.2 Definition of Hazardous Locations 95 6.11.3 Design Features 96

7 INSTRUMENTATION AND CONTROL EQUIPMENT (I&C) 97

7.1 Operation Levels 97 7.1.1 General 97 7.1.2 Operation Level 0 97 7.1.3 Operation Level 1 98 7.1.4 Operation Level 2 98 7.1.5 Operation Level 3 98

7.2 Operation Modes 99 7.2.1 General 99 7.2.2 Manual 99 7.2.3 Step by Step 99 7.2.4 Automatic 99

7.3 Design Criteria 100 7.3.1 General 100 7.3.2 Sizes of Indicators, Recorders, etc. 100 7.3.3 Transmitter Racks and Piping 101 7.3.4 Special Local Conditions 101


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7.4 Measuring Systems 101 7.4.1 General 101 7.4.2 Flow Measurements 102 7.4.3 Temperature Measurements 102 7.4.4 Pressure Measurements 102 7.4.5 Level Measurements 103 7.4.6 Electrical Measurements 103 7.4.7 Position Measurements 104 7.4.8 Limit Switches 105 7.4.9 Contact Devices 105 7.4.10 Vibration measurement 105

7.5 Interlocking and Lockout System 105

7.6 Tests 105

8 TRANSPORT AND INSTALLATION 106

8.1 General 106

8.2 Packing 106

8.3 Marking 107

8.4 Transport and Storage 107

8.5 Preparation and Installation 108

8.6 Reference Points 108

8.7 Installation Works 109

8.8 Civil Site Work 110

8.9 Safety Precautions 111

8.10 Fire Protection and Fire Fighting 111

8.11 Cleaning Up 112

9 INSPECTIONS AND TESTS 113

9.1 General 113

9.2 Test Certificates 113

9.3 Testing 114

9.4 Tests at Manufacturer's Works 115 9.4.1 General 115 9.4.2 Type Tests 116 9.4.3 Routine Tests 116

9.5 Tests on Completion 116

9.6 Reliability Run 117

10 STAFF TRAINING 118


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11 ANNEXES 119

Annex A Equipment Designation System -Application Guide Annex B Forms of Data Schedules Annex C Painting System Annex D Symbols and Abbreviations


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1 GENERAL REQUIREMENTS

1.1 General The Contractor shall strictly observe these General Technical Specifications (GTS) as far as they are applicable to the works. He shall carry out all work in a skilled and workmanlike manner in compliance with modern industry practice. All design, calculations, materials, works and Facilities, manufacture and testing shall conform to the latest applicable standards.

In addition, the Contractor shall conform to all applicable regulations regarding the execution of construction and installation work, and shall follow all instructions issued by the competent Authorities, and the Employer.

The Particular Technical Specifications (PTS) shall take precedence over the GTS in case of any contradiction.

1.2 Scope of Work The scope of work in this Contract is established in the PTS, GTS, the commercial conditions of contract, etc.

1.3 Standards The design, materials, manufacture, testing and performances of the Works shall comply with the latest current ISO/IEC Standards / Codes where applicable, and/or approved Standards or Codes, even if no reference to any Standard is made in the Specifications.

When the Contract Documents contain more restrictive requirements than those of the Standards or Codes, the Contract Documents shall prevail.

Any reference in the Contract to Standards and Codes or to materials and equipment of a particular manufacturer shall be regarded as followed by the words "or equivalent". The Contractor may propose for approval of the Employer alternative recognized Standards or Codes, materials or equipment, provided that they are substantially equivalent or better, in every significant respect, to those specified.

If the Contractor proposes deviations from the specified or approved Standards and Codes or desires to use materials or equipment not covered by these Standards and Codes, the Contractor shall state the exact nature of the change, the reason for making the change and the proof that these equipment or materials are substantially equivalent or better, in every significant respect, to those specified.

For applications where no relevant Standard exists, up-to-date recognized practice will apply.

Where ISO/IEC Standards / Codes or other Standards are referred to, the Edition shall be that current at the Reference Date, together with any Amendments issued to that date.

The Contractor shall keep on Site during the period of the site works the applicable Standards and Codes of Practice concerning the site works in general, and the field tests


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of materials and equipment in particular. One set of these documents shall be provided by the Contractor to the Employer. The list of these documents established by the Contractor shall be submitted to the Employer prior starting the site works.

1.3.1 Certification of Contractor The contractor shall have his own quality assurance system, adequate for designing, manufacturing and installing the works, conforming to an international standard such as ISO 9001, 9002 and certified by an internationally acceptable organization.

1.3.2 Standards for General Application Standard publications issued by the following organizations of standardization are considered being approved standards for the works:

- AGMA American Gear Manufacturer Association

- AISI American Iron and Steel Institute

- ANSI American National Standards Institute

- ASME American Society of Mechanical Engineers

- ASTM American Society for Testing and Materials

- AWS American Welding Society

- BS British Standards

- CCITT International Telephone & Telegraph Consulting committee

- CECT European committee for Manufacturing of Boilers & Kindred Steel Structures

- CMAA Crane Manufacturers Association of America

- DIN Deutsches Institut für Normung

- IEC International Electrotechnical Commission

- IEEE Institute of Electrical and Electronic Employers

- IIW International Institute of Welding

- ICEA Insulated Power Cable Employer's Association

- ISO International Standards Organization

- JEC Standards of the Japanese Electrotechnical Committee

- JIS Japan Industrial Standards

- NEMA National Electrical Manufacturers Association


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- NFPA National Fire Protection Association

- VDE Verein Deutscher Elektroingenieure

- VDI Verein Deutscher Ingenieure

- SIS Swedish Standards Institute

1.3.3 Basic Design, Manufacturing and Testing Standards

ISO System for Limits and Fits, Part I, General Tolerances and Deviations

ISO/R286-1963 ISO/R1829-1975

Permissible Machining Variations in Dimensions Without Tolerance Indication

ISO/2786-1973

Screw Threads ISO 68-1973 ISO 262-1973 ISO/R724-1978

General Principles for the Verification of the Safety of Structures

ISO 2394-1973

Methods and Definitions for Mechanical Testing of Steel Products

ASTM-A370

Tension Testing of Metallic Materials ISO/R82-1959

Notched Bar Impact Testing of Metallic Materials

ASTM-E23 ISO/R83-1976

Bend Test for Steel ISO/R85-1959

Liquid Penetrant Inspection ASTM-E165

Recommended Practice for Radiographic Testing

ASTM- E94

Ultrasonic Examination of Heavy Steel Forgings ASTM-A388

Guided Bend Test for Ductility of Welds ASTM-E190

Welders' Qualification Tests AWS (American Welding Society) Group B, DIN EN 287

Preparation of Steel Surfaces for Painting by Sandblasting

SIS 05-5900

Designation of Degree of Rusting of Painted DIN 5321


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Surfaces

Certificates of Material Testing DIN 50049

1.3.4 Material Standards ISO, ASTM (American Society for Testing Materials), AISI (American Iron and Steel Institute), DIN (German Industrial Standards) and BS (British Standards) are approved standards for the supply of materials.

Material tests according to DIN 50 049-3.1 C shall be provided for all important parts of the equipment such as: steel plates for parts under hydraulic pressure, all major castings (runner hub, runner blades, wicket gates etc.), large forgings (turbine and generator shaft etc.), high stressed large bolts etc.

For less important parts, certificates according to DIN 50 049-2.3 are acceptable.

Materials shall be new and of adequate quality, suitable for the purpose, free from defects and imperfections, and the classifications and grades in conformance with the latest issue of the respective ISO, ASTM, AISI, DIN or BS standard. Material specifications, including grade or class data, shall be shown on the appropriate detail drawings submitted for review.

If using stock material not specifically prepared for the works under this Contract, the Contractor shall submit evidence that the material complies with approved standards and that the material is adequate for the intended use.

The Contractor shall indicate in the Data Sheets, the materials and applicable standards for all major parts of the supply.

The materials shall be carefully selected for the intended purpose and due consideration of the site conditions and the tropical environment.

1.4 Units of Measurements The international SI-system of units shall be used for all documents, calculations, correspondence, drawings, etc. with the exception of pressure to be indicated in bar.

1.5 Works Identification System The various components of the electrical & mechanical installations, equipment, appliances, conductors, cables, terminals, etc. shall be allocated and indelibly marked with a unique tag number, which shall be used to identify the equipment both on drawings and in the field.

The Contractor’s Works Identification System shall be submitted for the Employer's approval prior to implementation. The Employer may select one joint Identification System for the entire Project (including works beyond this contract) and reserves the right to deviate from the Contractors proposal.


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The system shall be based upon area codes allocated to each main area (e.g. control room, relay room, switchyard, turbine room), an equipment code composing an equipment identifier and a unique sequence number.

Extracts of an application guide of proposed Equipment Designation System (EDS) based on IEC Standards 61082 and 61346-1 and DIN Standard 40719, Part 2 for all mechanical, electrical and Instrumentation and Control (I & C) of the project, is enclosed in Annex A, Chapter 11 for reference.

1.6 Construction Program The progress of the work shall follow the Overall Program of Works on which the Contract is based.

The "Construction Program" shall be submitted in accordance with the Commercial conditions of contract, and shall include the following information for individual parts or equipment:

− Design work

− Model Testing

− Shop work

− Shop Testing

− Transport to the Site

− Preparations at the Site

− Erection and commissioning

− Acceptance testing

− Trial operation

− Handing over

− Removal of erection equipment and clearing of the Site

− Interdependence with work of other Contractors.

The Contractor shall pay particular attention to the dates established for the submission of installation and foundation drawings with loading data, anchoring details, etc. and to all information necessary for the preparation of the civil work design drawings.

Since the scheduled dates are dependent on the progress of other site works the Contractor shall coordinate his operations at the Site with those of other contractors and the Employer respectively.


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2 TECHNICAL DOCUMENTS

2.1 General This sub-section specifies the general scope and gives a definition of the documents which, together with those listed in the Particular Technical Specifications, shall be delivered by the Contractor to the Employer in compliance with the commercial conditions of within the periods, and in a number and quality as specified in the commercial conditions of contract.

Technical documents means all drawings, diagrams, specifications, lists and schedules, operation and maintenance manuals, and technical information of a like nature provided by the Employer to the Contractor or submitted by the Contractor to the Employer under the Contract.

Technical documents provided by the Contractor shall be folded down to DIN Standard size A4 in size. Prints shall be on durable paper, with dark lines on a white background. The Technical documents shall show the following particulars either on the title page for A4 size or in the lower right hand corner for A1 or A3 size:

• Name of Employer

• Name of Consultant

• Name of Contractor

• Project title

• Contract number and title

• Title of technical documents (location, item and detail)

• Scale

• Date of technical documents

• Technical document number

• Revision identification

• Serial number in accordance with drawing classification system

• Signature of the Contractor’s Representative.

A blank space 90x60mm shall be provided as an extension of the title block for the Employer's approval stamp. Provision shall be made for details of revisions to be recorded above the title block.

The design and drawings shall be submitted in such sequence as to facilitate the Employer's review and shall be complete in regard to all computations and data. All technical documents shall be printed on DIN Standard size sheets and shall be clearly legible and neat.

Unless specified differently elsewhere a period of twenty eight (28) days after the receipt of design and drawings shall be allowed for approval or comments. Another one (1) week shall be allowed for return mail.


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Claims or extensions of time will not be granted on account of late submission of drawings to the Employer or for delay caused by drawings not approved by the Employer and requiring re-submission. Should the Employer deem a longer period of time necessary for checking certain drawings, he shall inform the Contractor to that effect in writing, within 21 days of receiving such drawings.

One copy of the submitted drawings will be returned to the Contractor with one of the following stamps:

"Approved", or

"Approved Except as Noted" (authorizing the Contractor to proceed with the Contractual works taking account of the Notes) or

"Returned for Correction and Resubmission".

In every case, these drawings, etc., shall be submitted in time to permit modifications to be made without delaying the completion of the works.

Technical documents, which are returned for correction shall be revised and resubmitted by the Contractor within 14 days for the final approval. All materials ordered or work performed prior to approval of the relevant designs or drawings by the Employer shall be at the Contractor's risk. When the Contractor prepares his Contractual Construction Program, he shall make allowance for and indicate the dates expected for submission and resubmission of technical documents by the Contractor. He shall also indicate the time for comments and for the approval of the technical documents by the Employer.

All cost for preparation, submittal, modifications and re-submittal of all documents and information required under this Contract shall be deemed to be included in the contract price.

The Contractor shall submit copies of each technical document in accordance with the “Document Distribution Matrix” and Milestone Schedule to be found in the Commercial conditions of contract.

The Employer reserves the right to request from the Contractor additional documents as may be required for proper understanding and definition of constructional, operational, coordination or other matters.

The Contractor shall cooperate with other Contractors in the exchange of drawings, dimensions, data and all other information required to ensure proper coordination of the work. All documents to be supplied shall be submitted in accordance with the agreed program so that any comments and changes requested by the Employer can be taken into account before starting of the manufacturing in the workshop and/or erection or installation at the Site.

If the Contractor fails to submit such documents, then the later execution of changes requested by the Employer and the resulting additional cost and/or delays shall be the Contractor's responsibility.

The preparation of drawings, computations or other technical documents shall not be sublet by the Contractor without the written authorization of the Employer. In such a case the Contractor shall be fully responsible for such drawings, computations and other technical documents as if he were the author.


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On drawings, catalogue sheets or pamphlets of standard Works submitted to the Employer the applicable types, paragraphs, data, etc., shall either be marked distinctively or the non-applicable parts shall be crossed out. Documents not marked in such a manner will not be accepted and approved by the Employer.

If required for proper understanding of the documents, additional descriptions/ explanations shall be given on these documents or on separate sheets. All symbols, marks, abbreviations, etc., appearing on any document shall clearly be explained by a legend on the same document or on an attached sheet (if not used in accordance with the Works Designation System agreed).

Each device appearing on any document (drawing, diagram, list, etc.) shall clearly be designated. The abbreviation mark used for an individual device shall be identical throughout the complete documentation so as to avoid confusion. All documents shall have a uniform title-block agreed by the Employer. Beginning with the very first submittal to the Employer, the Contractor's drawings shall bear a serial number corresponding to a drawing classification plan to be agreed upon by the Contractor and the Employer.

Revised technical documents replacing previously submitted documents shall be marked accordingly. Also, the revised part in the Document itself shall be marked clearly with cloud mark.

2.2 Drawings

2.2.1 Loading Drawings For all larger pieces of Works which, due to their dimensions and/or weight and transport limitations, will require special means for their transportation, the Contractor shall submit binding loading drawings indicating dimensions, weights, etc., of the respective pieces of Works and the necessary trailer for its transportation to the site.

2.2.2 Foundation Drawings If a piece of Works requires its own foundation or needs a special area for installation, the Contractor shall submit drawings indicating all pertinent dimensions, static and dynamic loads, etc. They shall include all essential details required for proper design and construction of the foundations and/or buildings.

In addition, they shall include openings, sleeves, slopes and the arrangement of any supporting structure, i.e. base-frames or other steel constructions for permanent fixing or erection purposes.

If conduits are to be installed in the foundations, the relevant information such as diameter, length, and purpose shall be indicated on the drawings.

2.2.3 Arrangement and Layout Drawings All layout drawings shall be drawn to scale. The General Arrangement (Layout) Drawings shall show the physical arrangement of Works (constructions, machines, complete switchgears, control panels, instrument cubicles, etc.), civil constructions


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(buildings, rooms, foundations, ducts, etc.) and reserved areas (for pipes, cables, lines, etc.) in relation to each other and to agreed coordinates and boundaries.

The Arrangement or Layout Drawings of electrical, instrumentation and control equipment shall indicate the location of all apparatus wherever used, i.e. in or on machines, control boards, switchboards, cubicles, control desks and panels, etc. The apparatus shall be denominated with the same standardized abbreviations and EDS codes as used in all other documents.

These drawings based on Tender Drawings and such further drawings which may be furnished to the Contractor by the Employer, shall take into account the functionality, the requirements for erection, operation, accessibility and maintenance of each item of the Plant.

2.2.4 Outline Drawings The Outline Drawing shall show all elements and the main dimensions of individual components where necessary in plan view, cross-section, side and top views. If reasonably possible such dimensions can be shown on Arrangement and Layout Drawings.

2.2.5 Design Drawings The Design Drawings shall include the shop drawings, assembly drawings, erection drawings, piping diagrams and piping arrangement drawings, etc., showing the dimensions, design and data of all constructions, apparatus and Works to be furnished under this Contract.

The drawings shall - where applicable - substantially conform to the Tender Drawings and shall show:

• Details of manufacturing and treatment of major single work pieces specially manufactured for this Contract

• Assembly of the Works in plan and elevation with main dimensions

• Sub-assembly of the principal components of the Works with overall dimensions, adjustment and clearance tolerances, numbers of corresponding detail drawings

• Sub-assemblies in which the Contractor proposes to ship the Works

• All necessary details of the parts connecting to the Works supplied by others

• Location and sizes of auxiliary connections for oil, grease, water, air, electrical power etc.

• Location and size of the instruments and accessories provided

• Methods of lubrication and sealing

• Instructions for heat treatment, pressure tests, surface preparation and anti-corrosive protection


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• Full details of parts for which adjustment is provided or which are subject to wear

• Method and sequence of installation, field joints, erection and lifting devices, jacks, grout plugs, anchoring details, etc., if not shown on foundation drawings.

2.2.6 Installation Drawings The construction, mechanical, electrical and I&C Installation Drawings shall provide detailed information on the disposition of the various items of a system (e.g. transmitters, actuators, connection boxes, cubicles, pipes, valves, pumps, compressors, etc.) and of the piping, wiring (cable trays, conduits, ducts), grounding etc. included in the installation or assembly. They shall be based on dimension drawings of cubicles, rooms, buildings or areas containing the equipment.

2.3 Diagrams For electrical diagrams general reference is made in IEC 61082 parts 1-3 and DIN 40719 parts 1-11.

Function numbers as per ANSI C37.2-1991 shall be used for the designation of the protection relays.

2.3.1 Single-Line Diagrams This is a simplified diagram of the essential electrical Works and their interconnections. Each circuit shall be represented by a single line only. It shall contain all required technical information of the Works represented, e.g. voltage, current rating, capacity, short-circuit level, ratios, voltage variations, positive and zero sequence impedance’s, measuring transformer and protection relay indices, interlocks, kind of switch drive, code designation, etc.

Single-line diagrams of individual main components and switchboards shall additionally show the control, indicating, measuring, metering, protection, automatic, and other auxiliary electric devices (also limit switches, rheostats, hygrometers, etc.), separated for each individual installation site and location.

2.3.2 Circuit Diagrams The Circuit Diagrams shall show the power circuits in all phases with the main apparatus as well as the pilot circuits (measuring and control circuits). It shall show in full the functioning of part or all installations, Works or circuits with all required technical information.

The control part shall be subdivided into separately drawn "current paths", each showing all its components regardless of their actual physical location. The individual circuits are to be drawn in a straight line sequence, avoiding line crossings. The current paths (to be designated by numbers) shall be drawn starting from two horizontal lines which represent the control voltage source. All devices belonging to the Works or forming part of the Works or control devices shall appear between these two lines.

Contact blocks of the installed switches, contactors, relays and other apparatus which appear in the diagram shall be shown below the respective contactor coil, indicating by


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means of numbers and, if not on the same, also the page No., the current path in which the corresponding contact has been used.

Interconnections to other circuit diagrams shall be clearly marked by means of dotted line separations and the corresponding functional designation.

The power circuit portion of the installation shall be drawn at the left side of the drawing.

Circuit diagrams shall also contain all terminals and their correct designations. Terminals grouped together to terminal blocks of switchboards, distributors, etc., shall be shown on the circuit diagrams in one fictitious horizontal line surrounded by demarcation lines. If, for any reason, the current paths of circuit diagrams must be separated, the corresponding counter terminal has to be indicated by all means.

The representation of electrical Works and control circuits shall not be terminated at the limits of the scope of supply, but has to be extended beyond this limit by all switchgear, protective, measuring and monitoring equipment required for full comprehension of the whole circuit. All terminals and functions of Works to be supplied by others shall be taken over as well.

Standard Circuit Diagrams are patterns of circuit diagrams which have been standardized with regard to scope, arrangement, representation and allocation of Works with the aim of simplification and easy surveillance of electrical circuitry.

Circuit Diagrams shall be preferably drawn on A3 size and folded to A4 size. Circuit Diagrams drawn on A4 size shall be subject to the Employers approval.

2.3.3 Block Diagrams The Block Diagrams shall be used to show in a simplified manner the main inter-relationships between the elements of a system by means of symbols, block symbols and pictures without necessarily showing all the connections. The symbols used for the individual kinds of components, e.g. servo-motors, computing modules, etc., shall clearly be explained on the diagram or on an attached legend.

When recommendable, a Block Text Diagram may be prepared, consisting essentially of explanatory texts enclosed in outlines which are linked by lines showing the functional relationships that exist between the various parts of an installation, Works or circuit.

2.3.4 Logic Diagrams The Logic or Functional Control Diagrams (FCD's) shall be used for representation of logic and sequence controls, automatic control functions and interlocking by showing binary and analogue logic elements and their effect on the various process equipment disregarding their electrical realization. Logic function elements (AND, OR, NOR, NAND, STORAGE, ADD, MUL, PID, etc.) shall be used for processing and combining binary and analogue signals.

Step-by-step sequence diagrams for start/stop automatics shall be used.


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2.3.5 Terminal Diagrams Such diagrams shall be prepared for any type of terminal box, panel, marshalling rack, control cubicle, switchboard, etc., and shall show the terminals (properly numbered) and the internal and/or external conductors (wires or cables) connected to them.

The terminal diagram of each individual switchboard, terminal box, panel, etc., shall contain, but not be limited to the following information:

• terminal number of terminal board with targets (terminal number and current path) of incoming and outgoing cables and wires

• cable designation

• type of cable

• number and cross-section of conductors

• assignment of conductors

• number of spare conductors

• approx. length of cable and its destination.

2.3.6 Protection Coordination Diagrams These diagrams shall show in a graphical manner separately for each power supply circuit:

• a simplified single-line diagram of the circuit with technical data of all instrument transformers and relays

• coordinated tripping curves of related protection devices

• setting of the protection devices.

2.4 Material Specification Such specifications shall be prepared for all principal Works and installations. They shall describe the performance (design, material, dimensions, corrosion protection, etc.) of the Works and include a list of components providing information on the manufacturer, type and technical data to obtain the following:

• full information on the Works, completing the general requirements fixed in the Tender Specification by the data/information of the specific manufacture

• proof of compliance with Contract Specification

For standard proprietary equipment (for example valves, switchgear, control gear, relays, transmitters, indicators, lighting fittings, etc.) catalogues or pamphlets can be submitted.

The technical data of electrical Works shall include as a minimum:

• max. permissible ambient conditions (temperatures, humidity)

• rated current and rated output/capacity

• same data as above under specified severest site conditions


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• rated voltage and ratio or regulation/setting range

• max. service voltage (acc. to IEC)

• power frequency and impulse withstand voltages

• type and code No. of protection relays and of instantaneous or thermal releases directly attached to circuit breakers and contactors

• power requirements for each voltage level (AC/DC).

2.5 Lists and Schedules

2.5.1 General The Contractor shall, apart from drawings and specifications aforementioned, complete his design documents with various lists and schedules for his design (consumers (AC, DC and Uninterrupted Power), motors, sensors, instruments etc.) and for all items to be supplied by him (governing system, cooling system, I&C system, MCC, excitation, etc.).

The schedule forms shown in Annex B of Chapter 11 to this GTS present recommended examples of such forms and indicate information which shall be included (also in case other schedule forms should be used by the Contractor because of his own possibly available standard design documents).

2.5.2 Consumer (Motor) Data Schedule (MDS) As detailed as possible information concerning the electric consumers (motors, heating, etc.) shall be collected and filled-in the corresponding schedule "MDS" (see Annex B of Chapter 11).

Motor specifications shall include the thermal motor characteristic both for cold and hot condition, the start-up characteristic when running with the driven machine and all data required for selection of the appropriate motor protection relay (both for cold and hot condition) and for locked rotor protection.

At least the following information/data are required for electrical consumers (if applicable):

• Works identification number

• description

• manufacturer, type, rated data of driven machine

• manufacturer and type of electric motor/consumer

• rated capacity

• service factor (ratio between motor output and power requirement of the driven machine)

• rated speed

• rated voltage

• rated current


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• ratio of starting current to rated current

• ratio of pull-out torque to rated torque

• power factor at rated capacity

• efficiency at rated capacity

• power consumption at machine design loading

• total weight

• design/enclosure/cooling (according to IEC)

• duty (continuous/intermittent/start-up)

• starting method/permissible starting frequency

• denomination of feeder

• motor protection

• applicable Standard Circuit Diagram

• maximum number and overall diameter of power cable(s)

• manufacturer and type of bearing(s)

• manufacturer, type and quantity of lubricant, service interval

• manufacturer, type, number, size, spring pressure and service interval of brushes (if applicable).

2.5.3 Motor Starter Lists The motor starter lists shall include all starters and contactors used for motors and contain the following technical information as a minimum:


• electrical design data as nominal and actual current rating, voltage rating, coil rating, making and breaking capacity, mode of operation

• maximum power cable size

• maximum control cable size

• current transformer ratio, class and capacity

• type of protection relaying and catalogue number

• setting of protection relays and maximum continuous rating of the protected circuit

• type and current rating of the back-up fuses/MCB’s for the main and control circuits.

2.5.4 Feeder Data Schedule (FDS)

Instead of or additional to the single-line-diagram for the LV switchboards (MCC) a Feeder Data Schedule "FDS" (see Annex B of Chapter 11) shall be prepared, describing each single feeder with:

• Consumer identification number and main characteristics


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• Designation and main outfit of corresponding feeder part in the MCC concerned

• Designation and description of proposed cable feeder connection between the MCC and the corresponding consumer.

2.5.5 Cable Data Sheet (CDS) and Cable Laying Schedule (CLS) The main cable data proposed respectively required by the Contractor shall be specified by him in the enclosed sheets "CDS" and “CLS” and shall include for each individual cable the following information as a minimum:

• cable number, in accordance with Identification System.

• cable type

• rated voltage

• number and size of conductors

• overall diameter

• cable termination at each end

• connection point at each end with cubicle/Works identification and terminal numbers

• cable routing

• In case interconnecting cubicles are used, the lists shall be prepared to show:

• cable termination for incoming and outgoing cables

• interconnection wiring

A cable laying schedule shall be prepared by the Contractor as an instruction for following activities on site:

• Selection of suitable cable type for the particular connection and description of destination (on both cable ends).

• Terminal connection of cable cores (single wires) at both cable ends (destination 1 + 2).

• Laying of the concerned cable in a suitable (existing) cable route.

In addition to the Cable Data Sheets a table for each cable type shall be included, showing the reduction factors for the individual modes of installation at applicable ambient temperatures and grouping of cables.

2.5.6 Data Point List The data point list shall indicate all control signals, process signals, measurement signals etc., local as well as remote, and shall contain at least:

• denomination and description of signals

• signal type

• signal range


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• works identification number of source and receiver

• data of signal source and signal receiver

• information regarding how and where to proceed the data

2.5.7 Setting List This list shall describe all settings, which either lead to warnings, alarms, fast shut down, emergency shut down or characterize the system (such as time constants, hysteresis, chosen orifice diameter in control circuits etc.). The setting list shall contain at least:


• dimension

• setting value

• function

2.5.8 Alarm and Tripping List This list shall summarize all signals which lead to warnings, alarms, fast shut down, emergency shut down. The List shall contain at least:


• correlation of signals and warnings, alarms, fast shut down sequence and emergency shut down sequence.

2.5.9 Workshop Test Schedules Individual Workshop Test Schedules shall be prepared for Works/installations (such as turbines, governors, valves, gates, pipes, bifurcation, cranes, hydraulic hoists, machines, generators, transformers, switchgear, control gear, I & C systems, bus ducts, cables etc.) and shall contain at least:


• manufacturer

• place of manufacture

• place of test

• date of test

• objective of test (all individual tests)

• standards applied

• certification

• inspection (by Employer / Independent Test Authority / Contractor/ Subcontractor)

• release for shipment

• remarks


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On the above schedule or on separate sheets the Test Procedure shall be specified giving for each test item (kind of test) a description, test method / Standards, used instruments, sample/routine test, test judgment.

2.5.10 Site Test Schedules Scope as in above article “Workshop Test Schedules”.

2.5.11 List of Tools and Appliances Lists of Tools and Appliances shall detail for all tools and appliances included in the scope of supply:

• item and code number

• description

• quantity

• weight where applicable

• gross storage requirements (separate for open-air, indoor, air conditioned) for individual components

2.5.12 Spare Part Lists Spare part lists shall detail for all parts included in the scope of supply:

• item and code number

• description

• quantity

• weight where applicable

• gross storage requirements (separate for open-air, indoor, air conditioned) for individual components.

2.5.13 List of EDS Identification Numbers

This list shall contain the used Works identification numbers in alphanumeric order and for each of them a description (the defined Works denomination, for example as written on the Works label) and the location (short definition of outdoor area and level elevation or building/room with elevation and room number). The form of this list should be suitable for ordering of the designation plates and labels.

2.6 Calculations The Contractor shall submit to the Employer for checking, the appropriate calculations for determining the main sizes, dimensions and operational characteristics, clearly indicating the principles on which the calculations were based. The calculations shall include the formulae, standards, test results, basic assumptions, etc. Submission of computer calculations without baseline information such as derivation of the calculation method, applied formulas, definition of variables and constants, explanation of abbreviations etc., will not be accepted.


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The short-circuit calculations shall be performed in accordance with VDE Standard 0102, part 1, or IEC 60909 or 61660 for DC systems.

2.7 Installation and Commissioning Procedures

2.7.1 Installation Procedures The installations procedures shall describe in sequential steps the erection of major equipment and shall contain sufficient details regarding equipment preparation on erection bay, handling of large and heavy pieces, leveling, anchoring, site welding, site painting, erection checks, site pressure tests, site flushing and cleaning of hydraulic systems, alignment and run out checks.

2.7.2 Pre-Commissioning Procedures Pre-commissioning tests and procedures shall be described in sequential steps and in sufficient detail for the pre-commissioning of all electrical and mechanical equipment and shall contain all information required for checking of installations, ratings, cable terminal checking and operation test of all auxiliary equipment.

2.7.3 Commissioning Procedures The commissioning procedures shall sequentially and in sufficient detail describe activities and tests of the Plant.

2.8 Operation and Maintenance Manuals

2.8.1 Contents The Operation and Maintenance Manual shall contain the following information in sufficient detail to enable the Employer to maintain, dismantle, reassemble, adjust and operate the Plant.

a) Table of Contents

b) List of Illustrations

c) Introduction

The Introduction shall contain:

• A brief general description of the Work items

• A brief description of the use of the Work items

• Definitions of technical terms used in subsequent graphs of the instruction book

• A complete list of all items used in accordance with the Works Identification System.

a) Detailed Description


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Detailed description shall contain a complete and accurate description of the Works, all components and ancillaries, their assembling and dismantling. An accurate list stating clearances, tolerances, temperatures, fits, etc. shall be included.

b) Operating Principles and Characteristics

A brief summary of the technical operating principles of the Works, including diagrams, circuit diagrams, sequence diagrams, piping, etc.

c) Operating Instructions

The instructions shall be accurate and easy to understand, and shall contain the sequence of individual manipulations required for operation. The information shall be presented in such a manner that the contents of this paragraph can be used for instructing personnel in the operation of the Works. Tables, lists and graphic presentations should be used whenever possible for making the description readily understandable.

An appropriate trouble-shooting list shall be included in this chapter.

d) Testing and Adjustment

The entire testing and adjustment procedure required for the Works after overhauls and during operation shall be described.

e) Maintenance Instructions

This section is divided into five paragraphs:

• Preventive maintenance, indicating the inspections required at regular intervals, the inspection procedure, the routine cleaning and lubricating operations, the regular safety checks and similar steps.

The maintenance instructions shall include a tabular (or in other approved form) summary of the required activities sorted according to

• daily

• weekly

• monthly

• quarterly

• yearly

• (or other) cycles as applicable.

This document shall provide the maintenance staff of the Employer with a brief and yet fully comprehensive information including all references to the applicable, detailed service and maintenance instructions.

• Repair and adjustment, describing the inspections, fitting and dismantling of parts, fault tracing as well as repair and adjustment procedures.

• Spare part lists, containing all the necessary data for ordering spare parts. These lists shall include all spare parts; those to be supplied and those not to be


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supplied under the present Contract. The prices for each spare part (exceeding a unit price of EURO 100 or approximately 120US$) shall be indicated in the list.

• Tool lists, containing all necessary data for identification of tools to be delivered under the present Contract.

• List of suppliers and alternative suppliers and addresses.

f) As-built drawings.

2.8.2 Format and Compilation For the final O & M manual the text, diagrams, drawings, brochures and all other instructions content shall be reproduced in ink by letterpress or offset printing or in carbon by electrostatic printing. Reproductions obtained by using dyes, chemicals or photo-sensitive or heat-sensitive materials are not acceptable.

All text shall be on size A4 paper except that brochures of smaller sizes will be accepted for minor components of proprietary equipment provided they have adequate binding margins.

The main text shall be on white paper

The paper used in the final version of the O & M manual shall be of the following archival quality material:

− White sheets: 70 g/m² to 106 g/m2;

− Colored sheets: not less than 70 g/m2.

Diagrams and drawings provided as part of the O&M manual shall be size A3 wherever the original is size A3 or larger and size A4 for all others.

The manual shall be strongly bound in a durable stiff cover of the loose leaf binder type, bearing the title in approved legend. Bound volumes shall not exceed 29 cm by 32 cm in size and be more than 8 cm thick. All volumes shall bear on the spine an approved shortened version of the title.

The Employer will indicate in due time the type of cover to be used by the various contractors of this project.

The Employer may request the Contractor to adapt drawings (construction, single line, wiring, terminal diagrams, etc.) to drawings of another contractor in order to facilitate maintenance, surveillance, repair of faults, etc. Catalogue sheets, illustrations, printed specifications, etc., shall be checked and prepared by the Contractor in such a way that the figures, statements and data valid for the delivered sizes and types of the Works concerned are clearly marked. All figures, statements and data valid for sizes and types not delivered must be crossed out.

2.8.3 Revisions and Supplements The completeness of the manuals shall be checked during installation, testing, commissioning and trial operation jointly by the Contractor and Employer.


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If it becomes evident during the installation, commissioning trial operation and defects liability period of the Works that the Operation and Maintenance Manuals are inadequate or incorrect, the Contractor shall supply immediately the necessary supplements and corrections. This shall be handled in the following manner:

• Deletions

One sheet of errata, printed on pink paper, shall be issued indicating the pages and date of issue of those pages which are to be deleted and are no longer valid.

• Corrections, Revisions, Replacements

New sheet or sheets shall be issued to replace the wrong pages. Whenever a new sheet is added to the instruction manuals, this sheet shall be given the new date of issue and a revision symbol, and an indication "Substituted for ... " and a marking of the corrected/revised items.

• Insertions, Supplements

Insertions or supplements shall be accompanied by a new respective "Table of Contents" page, where the latter shall be handled as described above under replacements.

The revisions and supplements requested by the Employer shall be made by the Contractor at the Site as far as possible and shall be submitted in each case to the Employer for checking and revision as stated above.

Before issuing the "Taking-Over Certificate" as per General respectively Particular Commercial conditions of contract, the revised copies of the Operation and Maintenance Manual shall be submitted together with the specified number of complete sets of drawings of the Works as completed. The Works shall not be considered complete for purposes of taking over under the terms of the Commercial conditions of contract until the above documents have been supplied by the Contractor.

2.9 Progress Reports during Design and Manufacturing

During design and manufacturing the Contractor shall quarterly submit the progress reports in a format acceptable to the Employer, detailing the progress of the work during the preceding period The report shall contain (but not be limited to) the following information:

• A general description of the Works performed during the reporting period for each main activity including any notable problems which were encountered.

• The percentages of each main work activity completed during the reported quarter with reference versus the scheduled program. Appropriate comments shall explain any differences.

• The total overall percentages of design and manufacturing completed, with reference to the Contractor's Construction Program (CP). Appropriate comments shall explain any differences.


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• A list of activities scheduled to be started within the next period of two (2) months, with expected starting and completion dates. If the expected starting and/or completion dates are different from those shown on the CP, an explanation shall be given.

2.10 Test Reports During Manufacturing For all Tests carried out in the manufacturing period comprehensive reports have to be issued containing all relevant information such as description of test, tools and gauges used, data logs of readings, admissible values for readings, evaluation of results, etc. so as to allow to reconstruct fully the testing and results in a later stage.

2.11 Progress Reports During Installation at Site During erection the Contractor shall, before the tenth (10th) day of each calendar month, submit the monthly progress reports to the Employer, indicating the progress of the work during the preceding month. The report shall contain (but not be limited to) the following information:

• A general description of the Works performed during the reporting period for each main activity including any notable problems which were encountered.

• A statement describing the daily weather conditions and the possible impact to the overall CP.

• The total overall percentages of erection works completed, with reference to the CP. Appropriate comments shall explain any differences.

• The percentages of each main work activity completed during the reported month with reference versus the scheduled program. Appropriate comments shall explain any differences.

• A list of activities scheduled to be started within the next period of two (2) months, with expected starting and completion dates. If the expected starting and/or completion dates are different from those shown on the CP, an explanation shall be given.

• A list of expatriate personnel (by position) employed during the reporting period.

• A list of the Contractor's Equipment and materials presently located at the Site. Also a list of equipment and materials which arrived at the port of entry and is in the process of being cleared through customs.

• Progress photographs of significant events. The Employer may direct the inclusion of specific photographs if deemed necessary.

• Main items of temporary facilities constructed during the reporting period.

• A statement detailing the status of progress on the overall program and how to regain any lost time or set-backs which may have occurred.


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• A list of inoperable temporary equipment, and the estimated date when the repair will be completed.

• A statement about labor relations and an explanation of actual or potential problems.

• A listing of each accident at the site involving the hospitalization and/or death of any person.

• A statement concerning the effectiveness of the security program and a listing of any major thefts.

• A listing of the amount and date of any payments received during the reporting period and the amount of any monthly invoice which has been submitted but not yet paid.

• A list of claims (if any) submitted during the reporting period including the claimed cost and extension of time.

• A statement concerning potential problems and recommendations on how they could be resolved.

2.12 Test report during installation on site For all Tests carried out in the installation period comprehensive reports have to be issued containing all relevant information such as description of test, tools and gauges used, data logs of readings, admissible values for readings, evaluation of results, etc. so as to allow to reconstruct fully the testing and results in a later stage.

2.13 Commissioning Report The commissioning report shall contain all relevant test results, diagrams, settings and characteristic system data.


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3 SPARE PARTS AND TOOLS

3.1 Spare Parts All spare parts to be supplied shall be interchangeable with the corresponding parts of all the Works supplied under these Specifications and shall be of the same material and workmanship. They shall be replaceable without cutting or destruction of adjacent components.

After the Tests on Completion and before issue of the Taking Over Certificate, the Contractor shall identify the parts to the Employer. The parts shall be checked and inspected for damage by the Contractor. Functional tests and pre-settings of electrical and electronic parts shall be carried out to the extent possible. The Contractor shall re-pack the spare parts for permanent storage and place them in the storage area.

The Contractor shall not depend on use of the spare parts and consumable products ordered by the Employer, for carrying out the Works.

Acceptance of any spare parts will not take place before the Contractor has submitted the complete final detailed list of all spare parts and tools.

All spare parts shall be protected against corrosion and shall be marked with Works Identification System labels.

All spare parts, tools and materials shall be delivered in marked boxes of sufficient sturdy construction to withstand long term storage.

3.1.1 Specified Spare Parts The required specified spare parts are listed separately in the Particular Technical Specifications. The price for each listed special spare part shall be quoted individually in the Schedules of Quantities, Rates and Prices; the total price shall be included in the Tender Price.

3.1.2 Recommended Spare Parts If any additional spare parts are recommended by the Contractor, these shall be stated in quantity and description in the Schedules of Quantities, Rates and Prices for each item.

Orders for recommended spare parts shall be optional to the Employer for a period of two years after the date of Issue of the Letter of Acceptance.

The recommended spare parts will not be considered in the tender evaluation.

3.2 Tools and Appliances The tools, wrenches, etc. shall be unused. Customary tools for erection shall be of the forged and polished chrome-vanadium type. Use of special tools and devices for erection shall be allowed, but shall be approved by the Employer in each case. Special tools and devices shall be provided with means for ready identification.


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All lifting devices and wire ropes slings to be used at site shall be tested at works and test certificate shall be supplied to the Employer.

An itemized list and description of all provided tools, auxiliary devices, storage equipment, etc. shall be included in the Tender. Acceptance of any tool or device shall not take place before the Contractor has submitted the complete final detailed List of Tools and Appliances.

Ropes, slings etc. shall be handed over in new condition. The Employer shall be entitled to take over from the Contractor the entire erection tools, appliances, instruments at mutually agreed conditions.


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4 DESIGN AND MANUFACTURE

4.1 Design and Construction Requirements The following directions, information and technical requirements for layout, design and erection shall be observed as far as they are applicable to the Works to be offered. The technical requirements of the General Technical Specifications (GTS) are valid for all parts of the Works except where they are varied by additional and/ or special requirements, specified in the Particular Technical Specifications (PTS).

Any changes of the design of any part of the Works which may become necessary after signing the Contract have to be submitted in writing to the Employer for approval, being sufficiently substantiated and justified.

The Works shall be designed, manufactured, arranged and installed to provide functional design and neat appearance. All parts of the Works shall be arranged to facilitate surveillance, maintenance and operation. All control sequences shall be simple and rational.

The parts of the Works shall be designed and arranged so that they can be easily inspected, cleaned, erected and dismantled without involving large scale dismantling of other parts of the Works. They shall be designed, and manufactured in accordance with the latest recognized rules of workmanship and modern Engineering practice.

The regulations, standards and guidelines listed in these Specifications shall be observed in the design, calculation and manufacture of the Works.

All parts of the Works shall be suitable in every respect for continuous operation at maximum output under the climatic conditions and operating conditions prevailing at the Site.

Special attention shall be given to the interfaces between the different Packages. Problems arising in this conjunction shall be solved by the Contractor and be defined in writing.

For individual items of the Works, materials and design are to be selected which are best suited for the operating conditions to which the parts in question will be subjected. Only such design and types of Works shall be offered which has confirmed its reliability in long-term continuous operation. Innovations cannot be accepted for the Main Tender but can be offered as an alternative proposal, in accordance with provisions of the Instructions to Tenderers.

All live, moving and rotating parts shall be adequately secured in order to avoid danger to the operating staff. All electrical components shall be safely grounded.

Manufacturers shall take appropriate measure to prevent the ingress of dust into any Works (such as bearings, relays, control and measuring equipment, etc.) which may be endangered thereby.

Suitable lifting eyes and backing-out bolts shall be provided where required or where they will be useful for erection and dismantling.


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Pockets and depressions likely to hold water shall be avoided, and if not avoidable they shall be properly drained.

Parts of the Works principally intended for standby purposes shall be protected from corrosion by careful choice of material and if necessary, by additional means; these should not reduce their continuous standby readiness.

All design details and layout matters shall be discussed in periodic meetings with the Employer. The first design meeting between the Contractor and the Employer shall take place within 28 days after the date of Issue of the Letter of Acceptance. Further design meetings shall take place as agreed between the participants until the design work is completed.

4.2 Allowable Stress

4.2.1 General The layout of the parts of items of Works shall fundamentally consider the most severe conditions to which they will be subjected during testing and operation.

The dimensions of the parts which are exposed to repetitive and alternating stresses as well as to impacts and vibrations shall take into account the safety measures approved in practice.

4.2.2 Custom designed equipment such as turbine, generator, main inlet valve etc.

Static loads

The equivalent stress calculated according to the von Mises theory σmises in relation to the minimum yield point has to be within the following limits:

For uniformly distributed stresses:

– Normal operation: σmises / min yield point < 50%

– Exceptional operating conditions: σmises / min yield point < 60%

– Extreme load cases σmises / min yield point < 75%

For maximum local stress peak

For each load case the limit for maximum local stress peak has to be lower or equal to 1.3 times the value stated for static loads in the table above.

Dynamic loads

The design has to consider dynamic loads and ensure fatigue strength over the expected lifetime of the equipment of at least 50 Year with an appropriate safety factor being at least 1.2.


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Fatigue strengths of wetted parts

A reduction of the fatigue strength due to exposure to water or humid environment has to be taken into account by appropriate reduction of the endurance limit where applicable.

Definition of operational loading cases

The operational loading cases are defined as follows:

a) Normal operation means operation under load up to maximum permissible continuous output under maximum head, taking into account the effects of the water hammer and of the speed rise after load rejection under the most adverse combination of operating conditions.

b) Exceptional operating conditions mean the runaway speed, the occurrence of short circuit, the emergency closure of intake gate under flow, failure of protection device on the wicket gates, operation of servomotor with engaged blocking device etc.

c) Extreme load case means the pressure test etc.

4.2.3 Standard equipment Standard equipment such as standard type electro motors, standardized armatures, gear boxes, switches, etc. are not subject to the requirements specified above for custom designed equipment. The allowable stress levels shall reflect common industry practice to ensure high quality and durability of the equipment.

4.2.4 Hoisting equipment and steel structures The allowable stress levels for hoisting equipment and steel structures shall be as per applicable standards specified in the relevant chapters of GTS and PTS.

4.3 Design Criteria The plant equipment shall be designed for the worst of possible combination of the following loading conditions:

• All static and dynamic hydraulic loads,

• Forces due to short-circuits,

• All loads due to dead weight and frictional forces,

• Seismic or wind loads

• Thermal load and

• Other loads


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4.3.1 Seismic Loads The forces being caused by earthquake including hydraulic loads which may occur additionally shall be taken into account for the computations.

Moreover vertical and horizontal acceleration shall be combined in the most unfavorable way. For horizontal and vertical accelerations values stated in “Information for Tenderers” have to be observed.

Stresses resulting from these loads shall not exceed permissible stresses.

4.3.2 Wind Load Except where otherwise stated, the minimum basic wind pressure of 1,250 N/m2 shall be applied on the vertical projected area, multiplied with the following factor for the different type of structures.

For plane surface: 1.2

For a cylindrical surface: 0.7

For lattice member, at front side: 1.6

For lattice member, at rear side: 1.2

4.4 Standardization of Works Every effort shall be made to standardize parts and minimize costs of the Works throughout the Works in order to facilitate keeping stocks, maintenance, replacement, interchangeability, etc.

The Employer, therefore, reserves the right to request the different contractors to use uniform types or makes of Works and materials. The Contractor shall not be entitled to claim extra payment due to this request. This request shall especially be applicable to small mechanical and electrical Works such as:

• valves

• thermometers

• pressure gauges

• flow meters

• water level gauges

• sight flow indicators

• terminals and terminal racks

• indicating instruments and meters

• auxiliary relays

• LV circuit breakers, contactors, fuses

• motor protection switches

• control devices


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• lights, bulbs, plugs, sockets

4.5 Noise The noise level caused by the installed Works shall not exceed the following values if not otherwise stated in the PTS:

• Machine hall, workshops, etc. max. 90 dB (A) at any place 1 m distant from operating equipment.

• Offices, control rooms max. 55 dB(A)

The noise level definition and measurement shall be in accordance with ISO and IEC. The values stated shall be adhered to taking a normal civil construction into account. Particulars of the civil construction shall be submitted by the Employer at the Contractor's request.

4.6 Identification Plates and Labels

4.6.1 General Each major equipment such as motors, pumps, compressors, accumulators, transformers, cubicles, CT’s, VT’s, valves, instruments, etc. to be delivered under this Contract shall be equipped with plates and labels.

The plates and labels shall be inscribed in English language (except manufacturer's nameplates of small standardized components).

The plates and labels have to be made of durable non corrosive material, water-proof, oil-proof, and wear-resistant. Writing has to be easy visible, readable, durable and suitably protected against aggressive atmosphere and solar radiation.

Plates and labels have to be allocated in readily visible locations. The plates and labels shall be placed on durable surface (e.g. it is not allowed to put plate or label on the glass of a dial indicator). The material of the plate and the fixation of the plate shall not disturb the reliable operation of the works.

All plates and labels shall be protected during erection. Damaged or illegible identification plates shall be replaced by new ones.

4.6.2 Manufacturer's Nameplates The following data shall be shown in accordance with the relevant standards:

• manufacturer's name and address

• Work's serial number and date of manufacture

• main design data.

As a general rule, standardized components, such as small or medium-sized electric motors, transformers, instruments, etc., may be delivered with the manufacturer's standard nameplate which shall be completed or replaced at the request of the Employer.


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The design of the Manufacturer's nameplates for the main components such as gates, valves, hoists, servo motors, pumps etc., shall be submitted for the Employer's approval sufficiently in advance.

4.6.3 Identification Plates Each part appearing under a certain Work Identification System, figures or numbers in functional diagrams, piping diagrams, in the Operation and Maintenance Instructions, etc., shall be equipped with a plate showing the same figure or number.

Cubicles and similar units shall also bear this identification number on the rear side if rear access is possible.

4.6.4 Instruction Plates All plates showing designations or instructions for operation, safety, lubrication, etc., shall have a uniform design.

4.6.5 Warning Plates Warning plates shall be engraved in English and in local language(s) designated by the Employer.

The warning plates shall be subject to approval by the Employer.

4.6.6 Labels for Conduits, etc. Conduits have to be labeled where required.

4.6.7 Labels for Cables

Each cable when completely installed shall have permanently attached to each end and at intermediate positions as may be considered necessary by the Employer, non-corrosive labels detailing identification number of the cable, voltage, and conductor size.

The cable identification numbers shall comply with those of the cable list.

All cables in cable pits and at the entry to buildings shall be labeled utilizing the aforementioned type of label.

4.6.8 Rating Plates Rating plates shall provide information about the basic design parameters of the equipment, such as pressure, power, voltage, speed etc..

4.6.9 Single-Line Diagrams Each switchgear room shall be furnished with a copy of the final as-built single-line diagram detailing all electrical data and denominations, separate for each individual


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switchgear / distribution board / MCC, placed under glass and frame/wall mounted at an approved location.

The same applies to the Station Single-Line Diagram of which one copy shall be arranged in the control room(s).

4.6.10 Key System for Electric Boards Key interlocked switches shall be provided with locks for locking in the neutral position. Similar locks shall be provided for selector switches for locking the switches in any of the positions.

The locks or padlocks shall be coordinated for the different applications and shall be supplied with three keys. A key cabinet at the end of each board (distribution board, MCC, control cubicles, etc.) shall be provided for storing the keys of that board. All keys shall have six master keys to open any lock or padlock supplied. Each key shall have one identification label fixed above the key-hanging hook inside the cabinet.

The cabinet door keys shall be similar and shall be six (6) in number.

4.7 Corrosion Protection

4.7.1 Painting

4.7.1.1 Scope of Work The Contractor's services shall cover the procurement of all materials, and the preparation and application of the painting and other protective coats as specified. The Contractor shall provide a complete, reliable coating system.

4.7.1.2 Painting Materials Coating materials shall be standard products of a paint manufacturer with proven experience in the field of corrosion protection of the type of Works to be supplied.

The Contractor shall submit for the Employer's approval full details of the preparation, type of materials, methods and sequences he proposes to use to comply with the requirements for the protection of the Works.

The entire paint material for a particular specified paint system shall be supplied by one manufacturer only, who shall guarantee the compatibility and quality of the paint material. For multicoated painting systems each coat shall have a different color.

Paint material shall be delivered in unopened original containers bearing the manufacturer's brand name and color designation, storage directions and handling instructions. A complete list of the proposed paint material shall be submitted to the Employer.

With regard to materials, the Contractor shall submit full details including the source of the basic raw materials, volatile matter content, nature of solvent, number of components, type of coat, coverage, time interval between coats and number of coats, compatibility of each coat with the previous coat, toxic properties, physical properties,


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shelf life, resistance against chemical attack, resistance against ozone and UV-radiation, compatibility with drinking water standards, etc.

The Contractor shall describe in detail the treatment he proposes to apply in order to give adequate protection during transport, site storage, building and concreting and subsequent erection.

The different coats of primer and subsequent coats shall be each of different shades of color where practicable.

The Contractor shall submit to the Employer for approval an overall color scheme in accordance with Annex C of Chapter 11 and the Particular Technical Specifications, for the finished surfaces of all Works. All final coats shall be in the colors approved by the Employer. On request of the Employer, painting samples for the different coats and colors shall be provided.

All pigment, paints and primers shall be delivered to Site in sealed containers packed by the manufacturer. The manufacturer's instructions for preparation and application of all painting and protective coats shall be strictly observed.

Paint materials shall be stored and mixed by the Contractor in strict accordance with the manufacturer's instructions. Paint material shall be used before the expiration of the shelf life. All safety regulations shall be observed, especially with regard to fire.

4.7.1.3 Workmanship

(1) Contractor's Equipment

The Contractor shall observe all safety and health precautions to protect his workers and others during painting works. The necessary equipment, such as fans, air-conditioning units, safety masks, nets, etc. shall be provided by the Contractor. All equipment shall be in strict accordance with the respective safety codes and regulations assuring efficient work of high quality.

The Contractor shall be responsible for the collection and disposal of empty containers, dirty rags and other wastes. It shall also be the Contractor's entire responsibility to protect equipment and structures not being painted such as nameplates, instruments, panels, floors, walls, etc. and he shall provide and install all necessary drop cloths and screens.

(2) Preparation of Paint Material

Paint shall be delivered ready mixed wherever possible. Adding of diluting agents and mixing of two or multi-component systems shall be done in the field in accordance with the directions of the manufacturer. Mixing and homogenizing of the paint material shall be done by a mechanically driven paddle or agitator in the original container. After mixing, the paint shall be poured into a clean container to ensure that no settled pigments are at the bottom.

The Contractor's equipment shall be of perfect quality and servicing and maintenance must be guaranteed. Cleaning of equipment shall be consistently carried out at each working interval.


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(3) Surface preparation

The term "preparation", as used below, includes any cleaning, smoothing or similar operations that shall be required to ensure that the material to be painted attains a suitable condition.

To be ready for painting, a surface should be clean, dry and sound. The surface to be coated shall be free from any deleterious material liable to impair good paint adhesion or attack the coat.

For removing rust and mill scale on structural steel, piping and other steel surfaces, those parts suitable for sandblasting shall be sandblasted to a grade specified or required in accordance with SIS 05.59.00 (Sveriges Standdardiserings Kommission) or the American's SSPC-SP standard. This applies particularly to parts which will be in contact with water, exposed to heavy condensation and humidity or subjected to high temperature.

For health reasons, sandblasting with quartz sand shall be avoided.

Sand blasting shall be such as to obtain a smooth surface free of foreign matters with a roughness of min. 0.04 mm. Corundum or an equivalent mineral shall be used and the grain size of the blasting medium shall not exceed 1.2 mm.

All parts of the Works shall be sandblasted at the shop unless otherwise specified or approved by the Employer.

The Contractor shall proceed with blast cleaning only when the following time and relative humidity schedule for application of the first coat can be achieved and maintained:

Relative Humidity Time

85% or above Do Not Blast

80 - 84% 2 hours

70 - 79% 4 hours

60 - 69% 10 hours

50 - 59% 12 hours

30 - 49% 24 hours

under 30% 1 Week

Parts which cannot be sandblasted shall be cleaned of rust by power tool cleaning to the highest degree possible.

Hand or power tool cleaned parts of minor importance and not exposed to water or humidity may be coated with a quick-drying rust-proof primer formulated on a combination of synthetic resins (ready-mixed paint).

Hot-dip galvanized surfaces which are to be painted shall be lightly sandblasted prior to through cleaning.


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(4) Application

The most commonly used methods of application are painting by brush, roller, pressure and airless spraying equipment. Selection of the application method depends on the surface to be painted. The quality of the paint shall in no way be negatively influenced. The manufacturer's directions shall govern the choice of application method. Inaccessible surfaces shall be painted prior to erection with prime and finish coats according the specification. Areas inaccessible to spraying equipment shall be painted by brush. Corners and edges shall be pre-coated. Bolts, screws, studs, rivets etc. shall be painted as a whole with the complete paint system after erection.

The primer shall be applied to an absolutely clean and dry surface only. Temperature and dry-out time shall be in accordance with the manufacturer's directions. Whenever possible the prime coat as well as one intermediate coat shall be applied in-doors at the Contractor's shop.

During painting the air temperature shall be at least +5°C and the temperature of the items being painted must be at least 3°C above the dew point. During drying of the paint, the temperature shall not be below 0°C. For all paints the surface temperature of the metal shall not be higher than +50°C during the painting. Concerning special paints, the requirements set by the paint manufacturer shall be followed.

Cleaning and painting work shall be interrupted outdoors and in non-conditioned rooms under the following conditions: rain, fog, dew, polluting winds, sand and other dusts. Surface preparation and application of the first paint layer are parallel operations to be carried out within a maximum delay of 4 hours.

All painting shall be free of cracks and blisters and all runs shall be brushed out immediately. After application of the last coat the paint system shall be free of pores. After erection of the equipment all damages to painted surfaces shall be repaired. Welds, rusty spots, beads, flux deposits etc. shall be repaired and repainted. For touching up, the same materials shall be used as for the main painting work. Repaired finish coats shall be of the same appearance as the original coating.

Remove electrical plates, surface hardware, fittings and fastenings before starting painting operations. Carefully store, clean, and reinstall after completion of work.

Equipment requiring special knowledge, skills and tools shall be prepared to receive field coating and painting to meet requirements of the painting schedule.

Parts which are embedded in concrete must not be protected against corrosion. However, transition zones of large steel pipes and of steel linings shall be painted over a length of 1 m within the concrete, all other steel surfaces embedded in concrete over a length of 200 mm within the concrete.

In linings surrounded by concrete, surface preparation and painting works shall be carried out after all Works such as concreting, welding, grouting and cleaning have been completed. The Contractor shall take into account the local climatic conditions and use adequate installations for sandblasting, dust control and sand extraction.

A properly equipped paint shop shall be set up at the Site with a crew of specialists experienced and skilled in the preparation and application of protective coatings, to deal with all site-protective treatment.


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(5) Quality Control

The minimum dry-film thickness prescribed in these Specifications shall be observed. No measured thickness shall be less than the specified thickness. Where the minimum thickness is not achieved, the coat shall be repaired to reach the specified minimum dry-film thickness.

The dry-film thickness shall be measured by approved gauges.

For checks on porosity, the Contractor shall furnish a DC variable high tension test instrument with built-in pore counter. The test voltage shall not exceed 2,000 V. The tests shall not be performed within 0.5 m distance from uncovered, corrosion resistance surfaces.

Upon completion of each coat, the painter shall make a detailed inspection of the painting finish and shall remove from adjoining work all spattering of paint material. He shall make good all damage that can be caused by such cleaning operations.

A detailed inspection of all painting work shall likewise be made, and all abraded, stained, or otherwise disfigured portions shall be touched up satisfactorily or refinished as required to produce a first-class job throughout and to leave the entire work in a clean and acceptable condition.

Adherence tests shall be performed and the acceptance criteria shall be in accordance with ASTM D3359, Method A, and a Scale of 5B for ASTM B3359, Method B.

(6) Guarantee

The guarantee period for all painting shall be 5 years, starting from the issue of the "Taking-Over Certificate". This painting guarantee period shall be effective regardless of any other guarantee periods for the project or parts of the project.

At the end of the painting guarantee period the anti-corrosive protection of the painted or galvanized surfaces shall not have a degree of rusting higher than RE 1 (one) on the European scale of degree of rusting for anti-corrosive paints, (the corrosion committee of the Royal Swedish Academy of Engineering Sciences, Stockholm).

4.7.1.4 Painting Systems Annex C "Painting System" of Chapter 11, indicates painting materials considered suitable for the various parts of the Works.

The Contractor shall state in his offer the manufacturer and identification of the product which he proposes as an equivalent.

The manufacturer's painting system shall be generally used to the maximum possible extent, final coats (of boards and panels) shall be matching the adjacent installations (e.g. when combined together in one continuous row).


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4.7.1.5 Color Code For color of equipment the Contractor shall refer to the Particular Technical Specifications. If color code for equipment is not listed in the Particular Technical Specifications, it shall be agreed upon after award of the Contract.

The coloring of piping, moving parts, etc., shall be according to internationally recognized standards.

4.7.1.6 Repair of Primer and Finish Coats

(1) General

For touching up, the same paint shall be used as for the original painting work. Repaired finish coats shall be of identical appearance with the original and no different in the color shall occur. The Employer may require which are severely to be removed and repainted.

(2) Galvanized and Painted Structures

Repairs on galvanized and painted structures shall be carried out as follows:

Damages to painting and galvanization:

• Surface Preparation: Scraping, wire-brushing or grinding to Grade ST 3 according to SIS 055 900-1967.

• Repair of Coatings: One coat of 2-component epoxy resin zinc-chromate primer. Dry film thickness minimum 0.050 mm.

• Two coats of 2-component epoxy-resin micaceous iron oxide (mio) paint. Total film thickness min. 0.160 mm. The color of the paint shall be the same as originally applied.

Damage to Painting only:

• Surface Preparation: Thorough cleaning of the damaged surface i.e. removal of oil, grease, dust, etc.

• Repair of Coatings: Two coats of 2-component epoxy-resin micaceous iron oxide (mio) paint. Total film thickness min. 0.160 mm.

• The color of the paint shall be the same as originally applied.

(3) Painted Structures

Repairs on painted structures shall be carried out as follows:

• Surface Preparation: Scraping, wire-brushing or grinding to Grade ST 3 according to SIS 055 900-1967.


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• Prime Coat: One coat of 2-component epoxy resin zinc-chromate primer. Dry film thickness minimum 0.050 mm.

4.7.2 Galvanizing Unless otherwise specified, all structural steel including ladders, platforms, hand rails and the like and all exterior and interior steel surfaces of outdoor Works, as well as bolts and nuts associated with galvanized parts shall be hot-dip galvanized, electrolytic galvanized or sheradized, as may be appropriate to the particular case.

Galvanizing shall be performed in accordance with VDE Standard 0210 (Verband Deutscher Elektrotechniker).

(1) Material

For galvanizing, only original blast-furnace raw zinc shall be applied, which shall have a purity of 98.5%.

The thickness of the zinc coat shall be:

• for bolts and nuts, approx. 60 micrometer

• for all other parts, except for hydraulic steel structures or parts intermittently or permanently submerged in water, approx. 70 micrometer

• for hydraulic steel structures or parts intermittently or permanently submerged in water, approx. 140 micrometer, in accordance with "VDEW, Druckrohrleitungen - Association of German Electricity Utility Companies, Steel Penstocks".

(2) Cleaning

All material to be galvanized shall be cleaned carefully of rust, loose scale, dirt, oil, grease, and other foreign matters. Particular care shall be taken to clean slag from welded areas.

(3) Galvanizing of Hardware

Bolts, nuts, washers, locknuts and similar hardware shall be galvanized in accordance with the relevant standards. Excess speller shall be removed by centrifugal spinning.

(4) Straightening after Galvanizing

All plates and shapes which have been warped by the galvanizing process shall be straightened by being re-rolled or pressed. The material shall not be hammered or otherwise straightened in a manner that will injure the protective coating. Materials that have been harmfully bent or warped in the process of fabrication or galvanizing shall be rejected.

(5) Repair of Galvanizing

Material on which galvanizing has been damaged shall be re-dipped unless the damage is local and can be repaired by soldering or by applying a galvanizing repair compound; in this case, the compound shall be applied in accordance with the manufacturer's instructions.


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4.7.3 Finished Surfaces Where the finish is not indicated or specified, the type of finish shall be that type which is most suitable for the surface to which it applies and shall be consistent with the class of fit required.

Surfaces to be machine-finished shall be indicated on the shop drawings by symbols. Compliance with the specified surface shall be determined by the sense of feel and by visual inspection of the work compared to applicable "Standard Roughness Specimens", or with roughness feeler gauge instruments. Both "Standard Roughness Specimens" and feeler gauge instrument shall be procured by the Contractor at the request of the Employer.

4.7.4 Unfinished Surfaces As far as practicable, all work shall be laid out to secure proper matching of adjoining unfinished surfaces. Where there is a large discrepancy between adjoining unfinished surfaces, they shall be chipped and ground smooth, or machined to secure proper alignment.

Unfinished surfaces shall be true to the lines and dimensions shown on the drawings and shall be chipped or ground free of all projections and rough spots. Depressions or holes not affecting the strength or usefulness of the parts shall be filled in a manner approved by the Employer.

4.7.5 Protection of Machined Surfaces Machine-finished surfaces shall be thoroughly cleaned of foreign matter. Finished surfaces of large parts and other surfaces shall be protected with wooden pads or other suitable means. Unassembled pins or bolts shall be oiled or greased and wrapped with moisture-resistant paper or protected by other approved means.

4.7.6 Rounding, Chamfers, Edges The edges of surfaces to be painted shall be rounded (minimum radius 2 mm) or chamfered accordingly. This requirement must be stated in all shop drawings for the relevant parts.

4.8 Welding and Heat Treatment

4.8.1 General All welds shall be as shown in the detailed drawings and shall be made in such a manner that residual shrinkage stresses will be reduced to a minimum.

The Contractor shall submit with his Tender adequate information concerning the proposed:

• extent to which automatic welding techniques will be applied;

• extent to which manual welding techniques will be applied;


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• extent to which it is the Contractor's intention to use pre-weld heat treatment, post-weld stress relieving, full anneal stress relieving or normalizing consistent with the thicknesses and types of material proposed;

• weld electrodes, welding wire and flux which will be used with the selected plate material or materials;

• standard tolerances for the deviations of mating weld profiles.

4.8.2 Welding Pieces to be joined by welding shall be cut accurately to size including the required allowances. According to the proposed welding method, the welding edges shall be sheared, flame-cut or machined to allow thorough penetration and fusion of the weld with the base material.

The cut surfaces shall be free of all visible defects, such as laminations, surface defects caused by shearing or flame cutting operations. The edges and surfaces to be welded shall be free of rust, mill scale, grease, oil, paint or any other foreign matter. Welding over zinc primers shall be permitted subject to submission of a certificate of a recognized institution stating the pertinent limiting parameters for this welding procedure. In all other cases, welding over paint shall be prohibited; all painting materials next to the joint to be welded shall be removed well beyond the heat-affected zone.

Unless otherwise allowed by the Employer, all steel parts to be welded shall be manufactured of steel produced by the open hearth or electric, with a carbon con-tent not higher than 0.20 % and a phosphorous content of not more than 0.05 %.

Wherever welding is specified or permitted, a welding process approved by the Employer and conforming generally to DIN or other approved standards shall be used. Approval of the welding process shall not relieve the Contractor of his responsibility for correct welding, the use of correct electrodes and for minimizing distortion in the finished structure.

When the welding process has been approved by the Employer, the Contractor shall produce a record drawing to show the approved process. The drawing shall include details such as the form of edges to be welded, electrodes and other welding materials, welding sequence, etc. Changes in the welding process after the welding method has been approved shall require the consent of the Employer.

Where possible, welding shall be carried out in the workshop. Welding which has to be performed in the field shall be clearly so indicated on drawings.

The Contractor shall follow the steel manufacturer’s recommendations concerning electrodes, welding and material pre- and post heat treatment. Notwithstanding the above, the suitability of the electrodes to be used for welding and the welding methods to be used for both shop and field welding shall be demonstrated by trials and tests to the satisfaction of the Employer.

Additional copies of all records of all welding procedures, including preheating and stress relieving, chemical analysis and physical properties, shall be made available to the Employer upon request.


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Design, preparation, performance and testing of welded constructions shall suit the kind of stresses and the grade of risk, considering a supposed failure of the welded member.

The following table shows a general classification by means of numbers with the sig-nification of each number explained thereafter.

STRESS

Compression Bending, Tension >0.9 allowable stress

Alternating, Dynamic

Small risk Stairs, Rails, doors

0 0 1

Medium risk Cranes, roof trusses, bridges

2 2 5

High risk Penstocks, steel linings, spiral casing, guide vane, runner, draft tube, gates, stoplogs etc.

3, 4, 5, 6 3, 4, 5, 6 3, 4, 5, 6

Any structure not especially mentioned shall be classified by the Contractor and shall be subject to approval by the Employer.

Signification

0 = Without special prescriptions. Only skilled welders shall be employed which follow proven rules of workmanship.

1 = Full penetration welds. The weld preparation shall allow the filling of the weld profile without defects. The root of double welded butt joints shall be ground before welding the second side. If the second side is inaccessible for welding, such single welded butt joints shall be built up against a backing strip.

2 = Welder qualification test. All welders and welding operators shall have passed qualification test in accordance with the respective National Standard or rules of AWS-American Welding Society, or the DIN EN 287.

Weld ground flush. The weld shall be ground on both sides of the steel plate. The weld surface shall be finished so as not to reduce the plate thickness by more than 3%. Butt welds with a smooth surface and a chamfer of less than 8% of the width of the top layer need not be ground.

Connections rounded. Where stresses are to be deviated, already the design shall care for a reduced notch effect. Welds shall be smoothly ground and rounded.

3 = Welding procedure test. The Contractor shall describe the proposed welding pro-cedure. Further he shall prove with tests, that the properties of the weld and


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transition zone are at least equal to those specified for the base material. The welding procedure test may be combined with the welder's qualification test.

4 = Welding performance test, executed during fabrication and site welding. Run-off plates shall be tack-welded to one end of the plate under work. The weld shall continue on that run-off plate (test plate), welded in the same manner and under normal working conditions.

• One test plate is required every 20 m of weld seam, but at least one of each weld type.

• The laboratory tests shall cover the same range as the welding procedure tests.

• On request by the Employer test plates shall be welded in his presence.

5 = Ultrasonic and/or radiographic test. Depending on the location of the weld seams and the plate thickness, ultrasonic and/or radiographic tests shall be performed. The Contractor shall submit a proposal subject to approval by the Employer. If not stated differently in the Particular Technical Specifications, 20% of the weld length shall be radiographed, but at least one film per weld type. The Contractor shall record the results of the ultrasonic and/or radiographic testing in these reports and drawings.

6 = Marked with welder's stamp. The welder shall mark every seam welded by him with his number, so it can be recognized until the end of the fabrication period.

4.8.3 Welding Qualifications For welding of principal stress carrying parts (Medium and High Risk Welds, see above table), the standard of welding procedures, welders and welding operators shall conform to standards equivalent to the requirements of the ASME Boiler and Pressure Vessel Code, Sections VIII and IX, or DIN 8560, DIN 8563, EN 287

For welding of less important parts, the standards and qualifications shall conform either to the AWS Standard Qualification Procedure or equivalent standards.

All welders and welding operators assigned to the work shall have passed a perform-ance qualification test. If more than one year has elapsed since the welder or welding operator passed his last test, then he shall again be tested.

Welders' and welding operators' test certificates shall be submitted to the Employer, before the welding work is started.

4.8.4 Welding Work All welding (except welding of thin plates or piping of small sizes) shall be performed by the electric-arc method and where practical, with process controlled automatic machines.

The strength of welding of all equipment subject to high and /or alternating stresses, vibrations etc. shall be at least equal to the strength of the parts being weld-jointed.

Between plates and other sections where such stresses are to be transmitted only butt welds shall be permitted. All main butt welds shall have 100% penetration and where


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possible, shall be welded from both sides. The backside of the first run shall be suitably gauged out to clear metal before the sealing runs are deposited.

Butt welds on site which can be welded from one side only shall be provided with backstrips on the whole length of the seam to be welded. The backstrips shall be fixed to the downstream side of the upper element, to prevent accumulation of water and dirt.

For any welding work, only the appropriate welding rod, either arc or gas, shall be used. The properties shall conform to the material to be welded as specified in the respective standards.

The electrodes for arc-welding shall be classified on the basis of mechanical properties of the as-welded deposited weld-metal, type of covering, hydrogen absorption, welding position of the electrodes and type of current.

Electrodes shall be used only in the positions and under the conditions of intended use in accordance with instructions with each container. Electrodes for manual welding shall preferably be of the heavily coated-type and shall be suitable for welding in any position.

Tacks shall be removed before welding.

Electrodes shall be dried in electric ovens before use.

After being deposited, welds shall be cleaned of slag and shall show uniform sections, smoothness of weld metal, feather-edges without overlap, and no porosity and clinker. Visual inspection of the ends of welds shall indicate good fusion with the base metal.

Where weld metal is deposited in successive layers, each layer shall be thoroughly (peened ) before the next layer is applied.

The difference in thickness of adjacent butt welded plates shall not exceed 3 mm. Where plates of greater thickness are to be welded, a transition with a gradient of 1:5 shall be formed.

Welds shall be balanced as far as possible to minimize distortion and residual stress. Box type girders shall be welded in such a way as to be completely airtight.

All welds transverse to the direction of flow and the longitudinal welds of distributors, shut-off valves and manifolds shall be ground flush with the plates on the inside. Welds shall be ground flush on both the inside and the outside wherever dynamic stress occurs.

Particular care shall be taken in aligning and separating the edges of the members to be joined by butt welding so that complete penetration and fusion at the bottom of the joint will be ensured.

All pinholes, cracks and other defects shall be repaired by chipping or grinding the defects to sound metal and re-welding. Where fillet welds are used, the members shall fit closely and shall be held together during welding.

The ignition of weld electrodes shall not be started at the plate beside the weld, but at the seam flanks to prevent detrimental increments of local hardness. Where ignition points of electrodes are discovered, they shall be ground appropriately.


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Where auxiliary structural members are welded to components for the purpose of assembly or installation, these connecting welds shall be given particular care.

These auxiliary structural members shall be removed not by knocking them off, but by burning, followed by grinding the affected areas flush with the plate, without producing additional thermal stresses.

4.8.5 Heat Treatment The cost of any heat treatment prescribed by the manufacturer of the materials and the Contractor respectively for the welded parts to be supplied shall be included in the Contract Price.

Heat treatment of field erection welding seams shall be performed according to the specifications for the welding procedure for the corresponding parts, which shall be submitted to the Employer for approval.

4.8.6 Quality and Procedure Control Quality control methods, e.g., radiography, ultrasonic crack detection, etc., shall be done in accordance with the appropriate manufacturing code. However, the Contractor shall indicate clearly in the Volume 1, Sections 3 the extent to which these methods shall be used.

All welded joints which have to be tight shall be inspected or tested by dye penetration tests.

All major welds carried out on parts under hydraulic pressure shall be subject to at least 20 % radiographic and 100% ultrasonic examination. All welds on the skinplates shall be additional dye penetration tested as directed by the Employer.

The Contractor shall indicate in the corresponding drawings the type of non-destructive testing to be carried out during manufacture and at Site.

The following or other equivalent Standards shall apply:

• for radiographic examination:

DIN 54109 Non-destructive Testing; Image Quality of Radiographs of Metallic Materials

DIN 54111 Non-destructive Testing; Testing of Welds of Metallic Materials by X- or Gamma Rays; Radiographic Techniques

DIN EN 287 Quality Assurance of Welded Structures; Fusion-welded Joints Steel; Requirements Classification

AD-leaflet P 5/3 Manufacture and Testing of Pressure Vessels

• for ultrasonic examination:


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• According to the approved "Test and Examination Instructions" of the Contractor based on AD-leaflet HP 5/3.

All radiographic films and data shall become the property of the Employer.

Additional non-destructive controls can be required when it is desired to examine the acceptability of any welds when, in the opinion of the Employer, serious doubt exists as to their quality; in this case, the expense of this examination shall be borne by the Contractor.

When required in the Particular Technical Specifications, the detailed description of welding procedure (including type of welding electrodes, sequence of welding seams, etc.) for certain parts of the delivery shall be submitted to the Employer before commencement of manufacture.

4.8.7 Defects and Repairs Plates with laminations discovered after cutting shall be rejected unless the laminated portion is only local and can easily be repaired; such repairs shall require the consent of the Employer.

Defects in welds will be reported to the Employer. The Contractor shall use his discretion in determining whether or not it is advantageous to remove and repair the weld. His decision will require approval by the Employer.

Defects in welds which are to be repaired shall be chipped out to sound metal and the areas magnifluxed or ultrasonically tested to ensure that the defective material has been completely removed before repair of welding is carried out. The Employer shall be informed and given the opportunity of making an examination after the defect has been removed and before repair welding commences. Repairs shall be carried out in accordance with the relevant Standards and to the approval of the Employer. The Contractor shall be fully responsible for the in-service performance of all welding work.

The Work shall be 100% inspected again by the method used first to determine such faulty work.


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5 MECHANICAL WORKS, METAL AND STEEL STRUCTURES

5.1 General All mechanical Works and steel structures of any mechanical or electrical installation shall comply with this General Technical Specifications and the requirements of the Particular Technical Specifications.

The Works shall be of an approved, reliable design providing the highest possible degree of uniformity and interchangeability.

The design and arrangement of Works and installations shall facilitate erection, test, operation and maintenance.

All Works shall be pre-assembled in the manufacturer’s premises to an utmost extent.

Revolving parts shall be statically or, if required in the Particular Technical Specifications, dynamically balanced so that when running at normal speed and at any speed up to the maximum, there will be no vibration due to lack of balance.

5.2 Bolts, Screws, Nuts, etc. All bolts, studs, screws, nuts, and washers shall be to the ISO metric system except other standards will be considered for specific applications. The extent to which other standards are proposed shall be indicated by the Contractor. Bolts and nuts shall be hexagonal or socket headed. Sizes smaller than 4 mm shall be used only for instrument and relay internal connections.

Steel nuts and bolts shall be zinc or cadmium plated. Stainless steel bolts, nuts washers and screws shall be used in water or when exposed to high humidity, for holding renewable parts and parts made of stainless steel.

Where mild steel bolts and nuts are used, they shall be of the precision cold forged washer faced type if commercially available in the size required. All parts, other than structural steel work, bolted together, shall be spot faced on the back to ensure that nuts and bolt heads bed down satisfactorily. Bolts machined from bar stock shall not be used without approval of the Employer.

All bolts or studs which will be subject to high stress and/or temperature shall be of approved high tensile material with nuts of approved material. All bolts and studs larger than 60 mm in diameter which are not accessible for tightening and releasing by commercially available pneumatic impact wrenches shall be drilled for heaters or shall have an extension for pre-tensioning by hydraulic tools.

Washers shall be provided under bolt heads and nuts unless otherwise approved by the Employer. All ferrous nuts and bolts on Works items where dismantling may be required during the life of the Works shall have their threads coated with an approved anti-seize compound. When in position, all bolts or studs shall project through the corresponding nuts by at least one thread, but this projection shall not exceed three threads, unless more length is required for adjustment. All nuts and set screws shall be securely fastened, to prevent loosening due to vibrations, using spring washers, lock


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nuts, split pins, self-locking inserts or 'Loctite' as appropriate for the purpose and material used.

The Contractor shall supply the net quantities plus 10 % of all standard size bolts, screws and other similar items and materials required for installation at the Site. Any such rivets, bolts, screws, etc., which are surplus after the installation of the Works has been completed shall become spare parts and shall be wrapped, marked and handed over to the Employer.

5.3 Seals The material for large seals (such as for gate seals) shall be of non-ageing rubber material, which shall be unaffected by wetting and drying or temperature changes. In case the Contractor intends to supply synthetic rubber material, with or without fluoro-carbon cladding, he shall furnish the name of the manufacturer and technical data of the material for the Employer's approval.

The seals shall be mounted in such a manner that they are according to the purpose dust or water tight and shall be designed and mounted in such a manner that they are adjustable and can be readily removed and replaced. All adjusting screws and bolts for securing the seals and seal assembly in place shall be of stainless steel.

5.4 Protection Guards All moving parts of machinery including shafts, couplings, collars, projecting key heads, gear wheels, and rope/belt-drives shall be completely guarded to provide full protection. The guards shall be of approved design and shall be fitted, where necessary, with inspection doors/openings. All guards shall be arranged so that they can be removed without disturbing the parts of the gears and Works which they protect.

5.5 Drives and Gears Gears shall be designed so that all stresses are within allowable limits when the maximum loads are being handled. All gears shall be designed and calculated in accordance with DIN, or equivalent international standards.

Where worm gears are used as a direct drive, they shall have the same load and time rating as the motors driving them. The gears shall work in oil and the temperature rise of the oil bath shall not exceed 40-50° C under normal working conditions at Site. The materials of the mating faces of worm wheel and worm shall be of a bronze/steel alloy.

Where practicable gear wheels shall be forced fit on the shaft and in addition, shall be keyed adequately to prevent any relative motion between the wheel and shaft. Where gears and couplings are secured in position by means of keys, they shall be easily accessible for tightening or removal. All keyways shall be machine cut. Couplings and collars shall be the shrouded or protected-type, free from projections of any kind.

5.6 Lubrication, Lubricants, Fuel Efficient means of lubrication, suitable for use under Site conditions, shall be provided for all moving parts.


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Self-lubricating types of bearings shall be given preference, unless otherwise specified or practicable.

The contamination of the air, water and soil by lubricants and fuel shall by all means be avoided by applying of an appropriate design and layout of the Works in conformity with the latest recognized standards for modern Engineering practice.

The number of different lubricants, transformer oils, oils for pressure systems, etc., used in the items of Works throughout the Works shall be limited to a minimum in order to facilitate keeping stocks and maintenance.

The Employer reserves the right to request the different Contractors to use certain types of lubricants, oils, etc. The Contractor shall not be entitled to claim extra payment for this request. All different types of oils, lubricants, etc., shall be stated in the Tender and are subject to the written approval of the Employer.

Unless otherwise stated in the Particular Technical Specifications, the first oil or grease filling for bearings, pressure oil systems, transformers, etc., including the necessary quantity for flushing and for the first oil change, shall be included in the Contract Price.

5.7 Piping, Fittings, Valves and Gates

5.7.1 General Unless otherwise stated, all piping shall be designed for minimum "nominal pressure" PN 10. All piping shall be tested with 1.5 the design/nominal pressure. All required piping shall be furnished complete with flanges, joints, expansion joints, gaskets, packing, valves, drains, vents, pipe suspensions, supports, etc.

Metric (DIN)-flanges shall be used throughout. Welded flanges shall be weld-neck or slip-on flanges.

Welding as well as application of corrosion protection coats shall be done in the manufacturer's shop to the greatest extent possible.

Flanged connections or joints shall be provided only as required for transport, installation or for reasons of dismantling for repair.

Joints between stainless and normal steel flanges shall be of the insulated type.

If the piping crosses over joints of civil structures of different settlement, the piping shall be provided with flexible joints to allow for vertical, horizontal, and angular deviations.

Piping installation shall be sloped to prevent trapping of air bubbles. Where required suitable venting system shall be provided.

Adequate clearance shall be given to parallel pipes to allow for easy maintenance without disturbing other lines. All overhead piping shall have a minimum clearance of 2.00 m from operating floors and platforms.

Where required water piping shall be provided with anti-condensation insulation.


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5.7.2 Water Piping and Fittings Pipe connections embedded in concrete shall be welded. Other pipe connections shall be flanged. The flange material shall be in conformance with the pipe material. The Contractor shall select the location of the welds as to ensure sufficient access for adequate touch-up treatment for corrosion protection.

Steel pipes of a diameter <100 mm shall be of stainless steel. Steel pipes larger than 100 mm in diameter shall be made of galvanized carbon steel.

Ductile iron pipes shall conform to ISO R 2531, class K9, fittings to class K12. Unless waived by the Employer, ductile iron pipes and fittings shall be mortar lined to AWWA C 104, double thickness.

Stress calculations of steel pipes shall be in accordance with DIN 2413, "Steel Pipes under Internal Pressure" or with "AD-Merkblätter; German Association of Manufacturers of Pressure Vessels, Memos”. The superimposed stress of bending, tension, compression, etc. shall not exceed the admissible stresses (stated in the above mentioned standards) at maximum applied load at any point of the piping.

The maximum applied load shall take into account test pressure, waterhammer pressure waves, thermal forces, dead weight, etc. On request of the Employer, a calculation on pipe stresses has to be submitted by the Contractor at no extra cost. The requested calculation will be subject to the Employer's approval.

The minimum steel pipe wall thickness shall be the "normal" or "standard" wall thickness as stated in the applicable standards.

Bends shall preferably be of the forged type. Mitered bends shall be allowed for larger sizes subject to the Employer's approval. For smaller fittings ductile iron will be permitted, too.

5.7.3 Valves, Gates Small valves and gates shall conform to DIN 3230, "Conditions and Terms for Delivery of Valves."

Generally, valves shall be leak-proof in either flow direction (except for non-return valves) when the nominal pressure is applied.

All valves with design pressures higher than PN 10 and diameters larger than DN 100 shall be workshop-tested to DIN 3230 for tightness and soundness of materials.

Valves shall close clockwise and be provided with position indicators. The drive units of motor-driven valves shall also be provided with handwheels for manual operation. The handwheel shall be operable under all conditions and shall be independent of the motor drive. Further, it shall not be rigidly coupled to the motor drive and shall not compulsory turn when the motor is energised.

To facilitate operation, large valves and gates shall be provided with by-pass lines for pressure balancing, if required.


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All valves shall be readily accessible for both operation and maintenance, and where necessary for ease of operation the spindles shall be extended and an approved form of pedestal hand-wheel provided at convenient operating floor level.

Valves spindles and pins shall be of stainless steel, spindle nuts and bushes of bronze, the body at least of improved C.I. (nodular cast iron).

All pressure reduction valves, safety valves and similar components shall be workshop-tested and provided with a work certificate 2.3 to DIN 50049.

5.7.4 Oil Piping Piping of a diameter < 50 mm shall be of non-corrosive material. Pipes larger than 50 mm in diameter shall be made of seamless steel. Pipe connections larger than 50 mm in diameter shall be provided with steel-flanged connections.

All piping shall be subject to hydrostatic test at a pressure 100 % greater than the maximum working pressure. The entire pipe arrangement shall be subjected to the pressure test after complete assembly at the site.

Oil pipes shall not be embedded in concrete. Oil pipes crossing civil structures shall be routed through sleeves embedded in the concrete.

All oil piping shall be acid-treated to guarantee clean surfaces, completely free from welding residues.

This treatment shall be applied to workshop and site manufactured piping respectively.

The piping can either be treated in an acid-bath or being completely filled with acid. The duration of the treatment shall be approx. 6 hours. After that the piping shall be neutralized, flushed and corrosion protected for final installation.

5.7.5 Pipe Supports and Hangers All pipework and accessories shall be mounted and supported in a safe and neat manner.

All brackets, stays, frames, hangers and supports for carrying and staying the pipes, including their fasteners shall be included in the supply and completed by the Contractor at the Site. Pipes and fittings shall be supported at or near flanges wherever possible.

Supports and hangers shall be designed and arranged so that any pipe can be withdrawn without disturbing the others.

All heavy valves and other mountings shall be supported independently of the pipes to which they connect, to the satisfaction of the Employer.

The Contractor shall supply drawings showing the location of each major anchor and support and the weight to be carried by that support.


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5.8 Mechanical Instruments All mechanical parts of instruments shall be suitably protected against shocks and vibrations, heat, humidity and splash water, etc.

Pressures gauges shall be provided with a damping liquid, e.g., glycerin, to compensate vibrations.

5.9 Pressure Oil Systems Pressure tanks shall be designed, fabricated and tested in accordance with approved standards. The appropriate inspection certificates shall be furnished. If the pressure is held by compressed air, then the requirements outlined in "Compressed Air Systems" of these General Technical Specifications shall also be applicable.

Oil sump tanks shall be provided with:

• suitable access openings

• fine mesh strainer combined with a magnetic filter through which all oil returning from the servomotors shall pass. The strainer shall be readily removable for cleaning.

• dehumidifying air filter

• flush-mounted oil-level indicator

• filling connection with a suitable strainer

• drain connection with hand operated shut-off valve.

Sump tanks shall be installed so that the bottom of the tank and the drain connection are at least 40 cm above the floor. The bottom of the tank shall be inclined in the direction of the drainage. The pumps shall be removable without the necessity of emptying the tank.

Servomotors shall be provided with suitable connections for pressure gauges on the pressure and suction sides of the piston. Servomotor piston rods shall be of stainless steel provided with a hard chromium layer of approximately 0.05 mm thickness.

5.9.1 Hydraulic Pressure Units Hydraulic pressure units for hydro-mechanical equipments shall be designed, fabricated and tested in accordance with standard DIN 19704-98 taken into account the special requirements described hereunder.

5.9.2 Manufacturing and Tests

Welds on pipes shall be of the homogeneous type; this means welding material shall be similar to pipe material.

Oil tank tightness shall be tested.

Before commissioning the power unit and the pipes shall be rinsed until is reached a grade of cleaning compatible with the power unit components.


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5.9.3 Maintenance It shall be possible to isolate any pressure generating device (pump, pressure

vessel, cylinder, etc.) from the pipe-work by means of lockable valves.

Large oil tanks shall include a manhole.

5.9.4 Safety The orifice controlling the minimum permissible opening/closing time shall be attached directly to the cylinder.

5.9.5 Oils Oil of an approved grade and quality shall be used for all purposes, like bearings, hydraulic systems, etc.

The number of different lubricants, oils for pressure systems, etc., used in the equipment throughout the plant shall be limited to a minimum in order to facilitate keeping stocks and maintenance.

Therefore the contractor shall submit the following information to the Employer for approval:

Oil trade name and classification according to ISO Standard 6743/0,

Kinematic viscosity at 50 C, in cSt,

Engler viscosity, in °E,

Total acid index, in mg KOH/g,

Solid impurities content, in %,

Water content, in %,

Flash point, in C,

Solidifying temperature, in C.


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The following table establishes the general quality requirements:

Oil Application Total Acid Index

in mg KOHg

Water Content

% in Vol.

Kinematic Viscosity

at 40 C in cSt

Solid Contamination

Servomotor-control Oil

Danger Threshold

Limit Condition

Danger Threshold

Limit Condition

Danger Threshold

Limit Condition

Danger Threshold

Limit Condition

Initial Index

+0.7

Initial Index

+0.9

Initial Index

+0.7

0.1 0.2 +/-15% of ref. value

+/-20% of ref. value

By particle counting

+1 Initial grade

By the gravimetric method

60 mg/l P < 80 bar 90 mg/l

30 mg/l 80 bar < P < 150 bar < 50 mg/l

15 mg/l P > 150 bar 20 mg/l

To be checked at the end of the warranty period

To be checked every third drainage

Foaming : In all cases to be visually monitored

The Contractor is responsible to ensure that the properties of the delivered oil do not exceed the threshold value.

If the threshold value is exceeded the Employer shall reserve the right to request either complete refill with the corresponding oil, or treatment of the oil and cleaning of the affected system, at Contractor’s expense.

5.9.6 Oil Tests Upon request from the Employer, the Contractor shall test the oil characteristics at his own expense.

5.10 Compressed Air Systems

The provisions for safety of the entire compressed air system shall conform to internationally accepted standards. The standards proposed by the Contractor will in any case be subject to approval of the Employer.

Vessels shall be of the cylindrical type and shall be mounted on a structural steel base. The inner surfaces of the vessels shall be protected with an appropriate paint coating or the vessels shall be hot dip galvanized. Each vessel shall be equipped with the following devices:

• 2 inlet sockets with valves

• 2 outlet sockets with valves

• 2 pressure safety valves

• 2 dial pressure gauges, one of the gauges with 4 electrical contacts

• 1 manhole or inspection hole

• 1 drain valve.


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In case the pressure vessel is used for pressurized oil or water systems, the vessel shall further be equipped with:

• 1 transparent level gauge with shut-off valves at both ends

• level indicators with electrical contacts in a number as required or specified.

Compressors shall be provided with:

• automatic lubrication

• air-intake filter and silencer

• thermometer for measuring temperature of the compressed air

• automatic shut-down if the discharge air temperature exceeds a predetermined, adjustable value

• discharging valves

• water drain valves

• water/oil separator

• pressure safety valve

• compressed air cooler

• non-return valve

• inlet pressure valve

• outlet pressure valve

• automatic moisture trap

The water / oil separator shall be equipped with an automatic solenoid-operated drain valve to achieve automatic draining during standstill. The compressor stages shall be equipped with discharge valves, which shall close time delayed after start to avoid compressor start against full pressure.

The compressors shall be delivered as package units on common frame with the appropriately sized AC squirrel cage motor and the respective motor starter panels, ready for operation.

Each vessel shall pass a pressure test at 1.5 x maximum working pressure for 8 hours in the manufacturer's workshop before coating is applied.

If requested by the Employer, each compressor shall pass a performance test in the manufacturer's workshop to a standard mutually agreed upon, e.g., DIN 1945, VDMA 4362, without extra cost. The readily assembled compressors, controls, and switch-gear shall be subjected to functional tests.

Each vessel shall be furnished with a test certificate of an independent, reputable underwriters' society.

5.11 Pumps Non-submersible pumps and motors shall be mounted on common frames and shall be of protection class IP 54.


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Materials of the pumps shall be:

casing cast iron (C.I.)

impeller bronze / stainless steel

shaft stainless steel

sleeves stainless steel

wear rings Bronze

keys stainless steel

The impeller diameters shall be neither maximum nor minimum impeller size for the selected pump size.

The pumps shall withstand corrosion and wear by abrasive matters within reasonable limits.

Shafts sealed by packing glands shall be fitted with sleeves. Seals shall be exchangeable without extensive disassembly of the pump. Leakage water shall be directed to suitable drainage facilities.

Each pump shall be fitted with:

• check valve at the discharge side

• air and drain valve

• pressure gauge.

The size of the pump motor shall be 15 % higher than the maximum power required by the pump at any operation point.

For submersible pumps, pump and motor shall be contained in the same casing and designed as a package unit with incorporated suction strainer and check-valve. Protection class for submersible motor and pumps has to be IP 68,.

The motors of submersible pumps operating in potable water shall not be filled with oil or other media detrimental to potable water. Motors of submersible pumps operating in dirty water may be filled with oil.

Dirty water submersible sump pumps with the motors mounted on top of the pump shall be suitable for running dry continuously, without damage to seals, bearings, or motors.

For all other items, the requirements described for non-submersible pumps shall apply.

For any pump, the overall pump-motor efficiency for the specified rated head and discharge shall not be less than 60%.

If requested by the Employer for pumps of a capacity higher than 30 kW, one in three pumps shall pass a performance test to DIN 1944, class II, with measurements taken at 0%, 50%, 80%, 100%, and 120% of specified discharge at rated speed. The results have to be certified in a workshop certificate 2.3 according to DIN 50049. For pumps of a capacity higher than 100 kW, the shop tests shall be compulsory; test certificate 3.1 B in accordance with DIN 50049.


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Prior to the test, the manufacturer shall provide certified motor performance curves.

5.12 Lifting Equipment

5.12.1 Design and Calculation Standards Generally, for design, stress calculation, manufacture and installation, the following standards and codes, besides other relevant standards and regulations, shall be applicable:

Design FEM rules for design of hoisting appliances 1998 (Fédération Européenne de la manutention)

CMAA, Crane Manufacturer's Association of America

ISO 4301-5: 1991, Cranes Classification; Part 5: Overhead traveling and portal bridge cranes.

ISO 7752-5: 1985, Controls-Layout and characteristics, Part 5: Overhead traveling and portal bridge cranes.

ISO 8566-5: 1992, Cranes - Cabins, Part 5: Overhead traveling and portal bridge cranes.

ISO 10245-5:1995, Cranes - Limiting and indicating devices Part 5: Overhead traveling and portal bridge cranes.

ISO 4308-1,1986, Cranes and lifting appliances- Selection of wire ropes, Part 5: Overhead traveling and portal bridge cranes.

ISO 4302: 1981, Cranes - Wind load assessment

DIN 4114, Steel Structures: Stability (part 1 and part 2)

ISO 8566-5, Cranes - Design principles for loads and load combinations.

DIN 15018, Cranes, Steel Structures, Calculation and Design

Manufacturing and installation

ISO 8306: 1985, Overhead traveling and portal bridge cranes, Tolerances for cranes and tracks

ISO 4310: 1981, Cranes - Test code and procedures

DIN 4100, Welded Steel Structures

DIN 15020, Rope Drives Safety devices for the operating personnel

Safety devices for the operating personnel shall be provided wherever it is deemed necessary.


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The safety rules outlined in VBG 8 of the German "Verband der Berufsgenossenschaft" or similar internationally recognized codes shall be observed.

Unless otherwise specified, the lifting equipment shall be classified to DIN 15020 as follows:

• for lifting capacity up to 100 kN (10 tons) "class 2 m", representing an average daily working time of 2 to 4 hours and an equal share of small, medium, and heavy loads (normal duty);

• for lifting capacity above 100 kN (10 tons) "class 1 Am", representing an average daily working time of 2 to 4 hours and a small share of heavy load lifts (light duty).

The Contractor shall state the various load combinations and factors of safety taken as a basis for calculation of the different components of the crane. In addition, the various factors of safety for the different load combinations shall be stated.

Each lifting equipment such as cranes or elevators shall be subject to a test operation with an overload = 1.25 x nominal load.

The crane girders and rails shall be calculated for a deflection not exceeding 1/1,000 of the span at maximum nominal load.

Steel structures of lifting equipment shall be of welded construction, which can be assembled at Site. All field connections and joints shall be bolted.

For maintenance, inspection and lubrication, appropriate ladders, platforms and steps shall be provided, fitted with anti-slip checkered plates, tabular handrails and skirting. Walkways, stairs and platforms for lifting equipment shall generally be designed for a service load of 3,000 N/m2.

5.12.2 Material Standards The material to be used for manufacturing lifting equipment steel structures shall conform to DIN EN 10025 or to the equivalent ASTM standards. However, the Contractor shall restrict the structural steel to FE 360 B and FE 510 C or ASTM A 36; the latter may be regarded as equivalent to FE 430 C. For these structural steels, connecting bolts and welds, the allowable stresses given in DIN 15018 shall apply.

If the Contractor intends to supply material other than that mentioned above, he can do so, provided that their equivalence to the specified material standards is verified by the Contractor and approved by the Employer.

5.12.3 Admissible stresses

The stresses between the track rails, their fixing elements and the concrete shall not exceed the following values:

mean allowable compressive stresses 6 MPa

allowable compressive stresses on edges 10 MPa

allowable bond stresses 0.6 MPa


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5.12.4 General Design Particulars Nameplates stating the nominal capacity in tons shall be attached to both sides of the lifting equipment structure and to both sides of the tackle. The printing shall be clearly legible from the floor.

Hoists, ropes, drums, sheaves and related Works shall be calculated to DIN 15020 or equivalent standards.

Flexible couplings shall be installed to relieve the bearings and shafts from any stresses due to misalignment and to facilitate the removal of motors, wheels and gears. The motor couplings also shall be of the flexible type.

All couplings, drive wheels and gears shall be press fit and keyed to the shaft.

All wheels shall have a hardened tread with a minimum Brinell hardness number of 400, and shall be made of carbon steel or low-alloy steel forgings. They shall have double flanges, shall be machined to a uniform diameter concentric with the hub bore.

All bearings shall preferably be anti-friction bearings designed to permit easy shaft disassembly and easy replacement. The minimum average lifetime under design load conditions shall be 50,000 hours.

All sleeve bearings except those for the hooks and rope sheaves shall be lubricated by central lubrication systems. An independent system for the trolley and one or two independent systems for the bridge will be acceptable. This central lubrication system shall satisfy the following requirements:

• the lubricant quantity for each bearing shall be variable

• lubricant filters shall be installed in every lubricating pipe

• the lubrication piping shall be arranged to be easily accessible for maintenance

For all high-speed gears and pinions, oil bath lubrication shall be provided. Low-speed gears may be lubricated with soft grease. Suitable oil and grease drip pans shall be installed and be readily accessible for draining and cleaning.

Bridge and trolley drives shall be equipped with a spring-set, electrically (solenoid or electro-hydraulic) released shoe or disc brake, with capacities of at least 1.5 times the full operating torque of the drive.

The brake shall be applied when the motor control switch or the main switch is in the "off" position and/or in case of power failure in any phase. The braking action shall be gradual and the brake shall become fully effective after a certain time lag.

5.13 Steel Structures Generally, design and stress calculation shall conform to:

DIN 1050 Steel Structures, Construction

DIN 4100 Welded Steel Structures, Calculation and Design


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DIN 4114 Stress Calculation of Steel Structures

DIN 18800 Steel Structures, Calculation and Construction

For standards applicable to steel structures of lifting equipment, refer to "Lifting Equipment".

The permissible design stresses for materials, bolts, rivets, etc. are given in DIN 18800.

Adequate clearance of at least 2 m shall be provided at overhead steel structures to allow unobstructed passage.

Stairs and ladders shall have an inclination of approximately 30° and 75° respectively. Stairs shall be complete with handrails, min. 90 cm high, and kickboards of 8 cm height.

Vertical ladders shall be installed alternating left hand/right hand side to horizontal platforms placed approx. every 10 m of vertical height. Vertical ladders of more than 2.5 m height shall be guarded. Load assumptions for ordinary platforms shall be:

• for platforms used by personnel and for support of light equipment with single weights of less than 500 N: 2,500 N/m2

• for all other platforms 5,000 N/m2

unless otherwise specified or stipulated in the applicable standards.

Platforms and stairs shall be provided with anti-slip checker plates.

The materials used for general steel structures shall conform to mild steel FE 360 B and FE 510 C or ASTM A 36.

5.14 Hydromechanical Equipment- Design and Manufacture

5.14.1 Selection of Equipment The type of gate, stoplog or valve shall be determined after considering the operating parameters, frequency of operation, importance and convenience of operation and maintenance and cost.

The following types are normally applied:

Regulating and sluiceway gate Radial gate, flap gate, fixed wheel gate

Intake and culvert gate Fixed wheel gate or slide gate

Navigation lock gate Miter gate

Navigation lock gate for passage of flood Sector gate

Stoplogs, bulkheads Slide gate


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5.14.2 Design Loads The equipment will be designed to withstand the worst possible combination of loads considering the operating condition and the frequency of operation, etc. Loads to be considered are as follows:

• Hydrostatic load: Hydrostatic load shall be the water head difference between the upstream and downstream sides of the gate, trash rack or stoplogs.

• Dead weight

• Wave height due to wind

• Sediment load

• Wind load

• Operating load

• Water pressure variation and vibration force induced by flowing water: Water pressure variation and vibration force induced by flowing water will be considered. The gate shall be capable of operating satisfactorily without vibration under any gate opening and conditions of water flow.

• Wave height due to earthquake

• Dynamic water pressure during earthquake

• Inertia force during earthquake: The Inertia force during an earthquake shall be the multiplication of the dead weight by the seismic intensity.

• Temperature loads: The effect of solar heating shall be taken into consideration.

5.14.3 Allowable Stresses The allowable stresses in the design shall be according to DIN 19704, DIN 18800 (EC 3) and the relevant standards.

5.14.4 Corrosion Allowance A corrosion allowance is not required.

5.14.5 Skin Plates

The minimum thickness of skin plates for gates and stoplogs shall be calculated using the DIN 19704:

for lock gates, barrage gates and safety gates 12 mm,

for other gates and inspection gates 10 mm,


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5.15 Gate Hoists

5.15.1 Operating Load The operating load of the hoist is the sum of the self-weight of the gate leaf, the self-weight of ballast if any, the friction loads due to the rolling, bearing and sealing parts, and other loads as follows:

• Dead weight of the gate leaf and/or ballast weight,

• Friction force due to rotating and/or sliding parts,

• Friction force due to seal rubbers,

• Buoyancy,

• Uplift force and down pull force,

• All loads resulting from the maximum torque of hoist motor under gate jammed conditions.

• Loads due to the action of earthquake according to Clause 3.2.1.2.

The closing force of all gates shall have an allowance of more than 25 per cent against the sum of all upward forces such as buoyancy, uplift, etc. at any gate opening under any reservoir water level.

5.15.2 Allowable Stresses The allowable stresses in the design will be according to DIN 19 704 and the standards refer herein.

The factor of safety for wire ropes of gate hoists should not be less than 8, as calculated by using the following equation:

FL

N≥ 8

where, F minimum breaking strength of wire rope

L normal tensile force acting on wire ropes

N number of wire rope falls to be used

5.15.3 Operating Speed For general use 0.25 - 1.0 (m/min)

For emergency closure gates, like power-intake 2 - 3 (m/min)

5.15.4 Motor Output

The capacity of all electric motors is to be more than that calculated from the following equation.


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[ ]Output W v kW=⋅⋅612. η

where, W operating load (tones)

v operating speed (m/min)

η total efficiency obtained by multiplying respective efficiencies of the mechanical parts as given below.

Table 3.2: Efficiencies of Mechanical Parts

Item Mechanical parts Efficiency

1 Drum 0.95

2 Sheave (plane bearing) 0.95

3 Straight & helical gear 0.95

4 Bevel gear reducer 0.80 - 0.85 with

5 Worm gear reducer 0.50

6 Oil-hydraulic hoists 0.85

* Friction coefficient

- Spindle screw 0.2

- Worm gear screw 0.06 - 0.1

5.15.5 Diameter of Wire Drum and Sheave The minimum drums and sheaves diameters for gate hoists are to be as follows:

• 25 - 32 times diameter of wire rope for drum

• 14 - 16 times diameter of wire rope for sheaves

Drums to have 2 spare turns on the anchor end and one spare turn on the other end.

5.15.6 Oil Hydraulics The oil hydraulic hoists and servomotors will be designed according to the guidelines of DIN 19704. The piston rod of servomotors shall be ceramic coated.

Hydraulic cylinder rods are to be sized to withstand earthquake vibration in the fully extended position without permanent distortion or damage.

5.15.7 Leakage of Gates Water leakage under any head and without the use of any additional sealing materials per m length of gasket:


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• for gates 0.1 l/s per m length of seal

• for stoplogs 0.2 l/s per m length of seal

5.16 Cranes and Lifting Equipment for Gates

5.16.1 Design Loads Design loads for cranes shall be according to DIN 15018 or FEM, but will be include at least the following:

• In service or operating condition:

• Dead loads due to dead weight.

• Live loads including the hook load multiplied by an impact factor of 1.3.

• Horizontal loads due to inertia and skew loads due to traveling.

• Wind loads during operation. For outdoor cranes, the in service design wind loads according to Clause 3.2.1.2 shall be applied.

• Loads due to collision with buffers.

• Loads due to the action of earthquake according to Clause 3.2.1.2.

Cranes for lifting gates, stoplogs and the like shall be designed after taking into account the operating load as set out under Section 3.2.2.1 of these design criteria.

• Out of service condition:

• Dead loads due to dead weight

• Storm wind load. For outdoor cranes, the storm wind pressure will be 1,250 N/m².

Fixed and moving crane structures and mechanisms are to be designed to withstand earthquake loading when in service or out of service without permanent deformation or failure.

5.16.2 Allowable Stresses The allowable stresses in the design shall be according to DIN 15018, DIN 15020 or FEM and the relevant standards given herein.

5.16.3 Operating Classification The group classification of all cranes is to be A3/M2 with a minimum life of 5 x 105 cycles in accordance to the FEM and DIN Standards.

5.16.4 Wire Ropes

The factor of safety of wire ropes is to be 6 based upon the minimum ultimate strength of the wire ropes.


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5.17 Quality of Materials and Equipment For general requirements concerning the quality of materials and Works refer to the General Conditions.

No welding, burning, filling or plugging of defective castings or any other defective components shall be permitted without the Employer’s agreement in writing. The repairing work shall be in accordance with ASME VIII Boiler and Pressure Vessel Code, Appendix 7, Examination of Steel Casting, Section 7-4 Repairs, Item D.

After the final heat treatment any steel casting, which has been repaired by welding, shall be tested for cracks by radiographic and/or gamma ray examination or any other tests which the Employer may require. The cost of these and other additional tests shall be borne by the Contractor.

Where stainless steel cladding consists of plates welded to mild steel sections, the welds shall be adequate to ensure that the stainless steel is securely fixed for all conditions of load and wear. Generally, all stainless steel parts shall be welded with stainless electrodes. The thickness of the stainless steel cladding shall not be less than 6 mm.

5.17.1 Material Preparation

5.17.1.1 Material Identification All components shall be clearly marked in accordance with the approved scheme for the identification of members, welds and welders according to ISO 9001.

The Contractor shall maintain full identification of primary structural steel throughout fabrication and the Contractor’s reference number shall be die-stamped, using round nosed dies or by paint marking, on cut sections of plate and sections, in a manner to be approved by the Employer.

5.17.1.2 Cutting and Edge Preparation The plate shall be cut to size by thermal cutting or machining in accordance with approved procedures. Cold shearing is not permitted.

The hardness of flame cut edges shall be limited to 325 HV10 maximum either by controlled speed flame cutting, by preheat, or by grinding back or machining after cutting.

The cut edges shall be 100 % visually examined for laminations, cracks, and other defects. If such defects are detected, the extent shall be established. A repair procedure shall be agreed with the Employer.

Any beveled edge that has been damaged shall be restored to the minimum tolerances. Where such restoration involves welding, only welding procedures approved by the Employer shall be used.

5.17.1.3 Forming of Curved Plates Curved plates and section shall be formed to the correct curvature by cold rolling without reducing the yield strength of the material. The procedure shall be approved by


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the Employer. The limit on the amount of strain induced by the cold process shall be 3 %. The finish product shall meet the requirements of the Committee Européen de la Chaudrainerie et de la Tôlerie (CECT) or BS 4360.

5.17.1.4 Straightening All rolled plates, bars and sections shall be flattened and straightened and made free from twist, without damage, before marking and cutting. The limit on the amount of strain induced by cold working shall be 3 %.

5.17.2 Spacing of Seams and Splices

5.17.2.1 Stiffeners Where required, transverse splices shall be located not closer than 120 mm intervals. The pitch of stiffeners for circular steel liners or penstocks shall be not less than 60 t (t is the thinnest liner thickness).

5.17.2.2 Splices Splices shall be kept to a minimum by making individual sections as large as possible consistent with the size of the plate supplied and the Contractor’s approved assembly sequence.

Splices shall be arranged to minimize overhead welding. Spliced materials of different widths and thickness shall have smooth transitions.

Lapped joints are not permitted.

When two or more members intersect or overlap at a joint, the order in which each member comes into the joint will be determined by wall thickness and/or diameter. The member with the thickest wall will be the continuous or through member, and the sequence for framing the remaining members shall be based on the order of decreasing wall thickness.

5.17.2.3 Beams Segments of beam with the same cross-section may be spliced. The use of the beam shall determine the location and frequency of splicing. In cantilever beams there shall be no splice located closer to the point of support than one-half the cantilevered length. For beams employed in any span between supports, there shall be no splice in the middle one-fourth of the span. Splices shall not be located closer together than twice the depth of the beams, or 900 mm, whichever is larger. The web splice shall be offset from the flange splice by a minimum of 100 mm.

5.17.3 Laying-out, Alignment and Fit-up

5.17.3.1 Laying-out At all stages during fabrication, the Contractor shall ensure correct positioning, alignment and levels in accordance with the required data.


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Overloading, damage or any permanent deformation of any of the structural components at any stage of the erection shall be rectified in accordance with a procedure approved by the Employer.

No structural welding shall commence until members to be joined have been properly aligned and braced to prevent distortion.

A minimum of toe-to-toe clearance of 75 mm shall be maintained between parallel welds.

5.17.3.2 Alignment and Fit-up for Welding and Tack Welding Whenever practicable, clamps, holding devices or other setting up fixtures shall be used in assembling parts of the structure to avoid temporary welded attachments or tack welding. In fit-up where clamps cannot be used, temporary spacer strips shall be used to ensure the correct root gap prior to tack welding.

Ring stiffeners, stiffeners and diaphragms shall be close fitted to the shape of the surface to which they are attached either by machining or by flame cutting and grinding.

At intersections, the utmost attention shall be paid to good alignment of the structural parts where members meet on opposite sides of a through member. As-built dimensions shall be used to align such plates and not theoretical dimensions.

5.17.3.3 Temporary Attachment Welds Temporary attachment welds are not permitted at steel liners and steels exceeding 500 MPa yield strength. All other temporary weld attachments and their removal shall meet the requirements of the Specification subject to the approval of the Employer.

5.17.3.4 Cope Holes Cope holes for ring stiffeners, stiffeners and diaphragms shall be permitted to a maximum radius of 25 mm. The cut edges of the cope holes shall be ground smooth to remove all notches, prior to fit-up of the member(s). The fillet portions of all welds are to be returned through the cope hole.

5.17.4 Temporary and Non-structural Attachments and Cut-outs

5.17.4.1 Welding Temporary and non-structural attachments shall be fitted to the shape of the surface to which they are attached, and welding shall be to an approved procedure by qualified welders. Temporary or non-structural attachments shall not be welded within 75 mm of any other structural weld measured from weld toe to weld toe.

Locations and fixing details of all temporary attachments are subject to the prior approval of the Employer.

Temporary attachments and cutouts are not permitted at steel liners and steels exceeding 500 MPa yield strength.


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5.17.4.2 Removal The removal of temporary attachments shall be either by thermal cutting or by grinding. If thermal cutting is employed, the attachments shall be cut off at a minimum distance of 5 mm from the surface of the material and then ground flush. Following removal, the area of the attachment weld shall be subjected to 100 % magnetic particle inspection.

Temporary attachments shall not be removed by hammering, or by any other technique, which may cause mechanical damage to the surface of the steel forming the main structure.

Following removal, any damage area shall be ground to merge smoothly with the original surface, and the surface is to be magnetic particle inspected. Where gouges up to 20 % of the steel member thickness have been made, then after grinding and testing they shall be repair welded to an approved procedure. Where gouges 20 % of the material thickness, the repair procedure or alternative solution shall be proposed by the Contractor and be subject to the approval of the Employer.

5.17.4.3 Temporary Cut-Outs The need for temporary cutouts shall be subject to approval by the Employer.

When temporary cutout are necessary, they shall be prepared with the same degree of care as for permanent cut-outs and shall be cut-out prior to erection of the member(s).

Special care shall be taken to ensure that the weld preparation applied to the cut-outs is appropriate to the final erected orientation of cut-out at the time of rewelding. The cutout shall be trial fitted prior to erection of the member. An approved welding sequence developed such that welding will be minimised shall be followed. All cutouts shall be prepared with rounded corners not less than 50 mm.

5.17.5 Finishing of Surfaces

Prior to completion, Contractor shall remove all burrs, tack welds and other marks made by welding, scaffolding or temporary bracing used in the fabrication procedures.

Any plate defects resultant from handling or fabrication works shall be repaired mechanically or to an approved welding procedure in accordance with the requirements of this Specification. The method applied for plate repairs shall be subject to the approval of the Employer and shall comply with limits of BS 4360.

5.17.6 Repair and Remedial Procedures

5.17.6.1 Repair Welding Welding repairs shall be carried out in accordance with Chapter 4 of these General Technical Specifications.

In the case of repairing a crack, the cause of cracking shall first be established satisfactorily before repair is allowed.


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5.17.6.2 Straightening of Distorted Members Prior to straightening of a distorted plate or rolled section, calculations of the strains involved shall be submitted to the Employer for approval. Members may be straightened cold prior to welding if the deformation does not exceed 3 % strain.

When carried out hot, the temperature of heated areas, measured by methods approved by the Employer shall not exceed 600º C. The part to be heated shall be substantially free of stress and from external forces except those stresses imposed resulting from the mechanical straightening used in conjunction with the application of heat.

Flame heating rectification shall be carried out only in accordance with approved procedures and with the agreement of the Employer in each specific instance.

Straightening procedures, which will include full details of methods of monitoring temperatures and times, are to be submitted to the Employer for approval prior to straightening. Methods of assessing the extent of any damage to the parent material by straightening are to be included in the proposals.

Hammering shall not be permitted.

5.17.7 Temporary Fabrication Aids Where possible, slings shall be wrapped around primary structural members for the purpose of lifting or rearing sections of the structure. Timber packers or other devices approved by the Employer and/or the Employer’s Representative shall be used to prevent distortion and damage, particularly where slings pass over protrusion such as stubs, flange outstands, etc.

Additional precautions shall be taken to ensure that miscellaneous projections such as pipes, pipe supports, nozzles, etc. are fully protected from interference with lifting slings during installation.

Adequate safety factors shall be used to cater for the effects of variation in self-weight, impact, dynamic effects and unequal sling lengths when determining lifting requirements.

Proper accounts shall be taken of the effects of differential deformation of support points during lifting. Structural calculations to investigate local member adequacy shall be carried out by the Contractor to prove the integrity of any lifting operation and shall be submitted to the Employer and/or the Employer’s Representative for approval prior to execution of the operation.

5.17.7.1 Temporary Bracing and Supports

Scaffolding supports and facilities for supervision and inspection of the work shall be provided as necessary. They shall be sufficiently solid to prevent deformation. Any anticipated deformation shall require an immediate stiffening of the structure.

Adequate temporary bracing shall be provided and shall be left in position until such as the structure is sufficiently far advanced for the bracing to be no longer required.


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5.17.7.2 Rectification of Surface Defects and Edge Laminations Surface defects revealed during fabrication or blast cleaning shall be treated in accordance with the requirements of DIN 18800 or BS 4360. Repair by welding of any surface defect or exposed edge lamination shall only be carried out with the approval of the Employer and using a procedure complying with BS 5135 or equivalent Standard.

5.17.7.3 Erection Loads and Stability During site assembly, the Contractor shall take account of all temporary erection loads imposed on the structure from supports, and slinging at each stage of the structure assembly.

At each stage of the structure assembly, the Contractor shall take account of the local or overall stability from self-weight and environmental loads; inclusive of scaffolding, staging, welding shelters and temporary works. The Contractor shall ensure that all stresses induced in the structure during fabrication and load out are within acceptable limits.

The Contractor shall take due consideration of the effect of wind on the structure or parts of the structure during construction.

The Contractor shall demonstrate to the satisfaction of the Employer that he has considered all relevant erection and temporary loads.

The Contractor shall produce a procedure for each erection or transport activity where the item under consideration exceeds 50 tons in weight, and at other times when requested by the Employer and/or the Employer’s Representative. The procedure shall cover all aspects and shall satisfy the requirements of the relevant standards.


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6 ELECTRICAL SYSTEMS

6.1 General The electrical items of any electrical or mechanical installation to be provided under this Contract according to the Particular Technical Specifications shall fulfill the requirements of this Section unless otherwise noted.

All components shall be of an approved and reliable design. The highest extent of uniformity and interchangeability shall be reached. The design shall facilitate maintenance and repair of the components.

The Works shall be pre-assembled to the highest possible extent in the Contractor’s or Sub-Contractor’s workshop, complete with all devices and wired up to common terminal blocks.

The power supply and control cables shall be laid up to these common terminal blocks.

Unless otherwise agreed, ratings of main electrical Works (in feeds, bus-ties) as selected or proposed by the Contractor shall generally include a safety margin of 10% under consideration of the worst case to be met in service whether originally specified or not. Prior to approval of such basic characteristics, the Contractor shall submit all relevant information such as consumer lists, short circuit calculations, reduction factors, etc.

Short-circuit calculations shall be evaluated giving full evidence that every electrical component can withstand the maximum stresses under fault conditions, for fault levels and duration obtained under the worst conditions.

All Works shall be suitable for the climatic conditions prevailing at site and other environmental conditions at the places of installation.

Outdoor installations shall be protected against solar radiation by means of adequate covers, where required.

The Contractor shall ensure that all the supplied Works is insensitive to any signals emitted by wireless communication equipment and to any capacitive or inductive interference.

In this General Technical Specification the following denomination is used for the voltage levels:

Low Voltage (LV) up to 1kV AC

Medium Voltage (MV) 1 kV AC to 36 kV AC

High Voltage (HV) > 36 kV AC

6.2 Standards The design, manufacture and testing of all Works and installations shall strictly comply with the latest edition of the relevant IEC publications.


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Regulations IEC 60364 for Electrical Installations of Buildings shall be compulsory.

6.3 Operation Voltage and Characteristic The following ratings refer to the values at the respective distribution boards.

The auxiliary power supply of the power plant is directly fed from the generator busbars through station service transformers. Transient voltage and frequency variations, exceeding the given AC-voltage and frequency range may not be excluded.

6.3.1 Low Voltage AC Power System

Nominal voltage between phases 400V +10% / -15%

Nominal voltage between phases and neutral

230V +10% / -15%

Frequency 50Hz + 4% / - 6%

Grounding system Neutral point solidly grounded

6.3.2 Direct Current and Uninterrupted Power Supply UPS

6.3.2.1 220V DC System

Nominal Voltage 220V DC +/- 15%

System configuration 2 wire – high resistance middle point grounding








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6.3.2.4 400/230V Uninterrupted Power Supply System

Nominal voltage between phases 400V +10% / -15%

Nominal voltage between phases and neutral

230V +10% / -15%

Frequency 50Hz + 4% / - 6%

Grounding system Neutral point solidly grounded

6.4 Electric Motors

6.4.1 General All motors shall be of approved manufacture and shall comply with the requirements of this Section. Motors of the same type and size shall be fully interchangeable and shall comply - as far as applicable - to IEC standard motor dimensions.

AC motors shall have squirrel cage type rotors. Only motors with a maximum speed of 1500Upm shall be used.

The general construction shall be stiff and rigid, no light metal alloy casings will be accepted. All precautions shall be taken to avoid any type of corrosion.

All motors shall be fitted with approved types of lifting hooks or eye bolts as suitable.

6.4.2 Motor Voltages and Power Ratings

The service voltages and corresponding power ratings for electric motors to be used shall be as follows:

Motors up to 100 kW:

Service voltage 3-phase 400/230 V AC

Mode of starting direct on-line up to 50 kW above 50 kW with suitable starters

Motors up to 0.75 kW:

Service voltage single-phase 230 V AC

Mode of starting condenser

Motors intended to work on the DC system:


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Service voltage 220 V DC

Mode of starting Resistor

6.4.3 Rating The rating of the motors shall be adequate to meet the requirements of its associated equipment. The service factor, being the ratio of the installed motor output to the required power at the shaft of the driven machine at its expected maximum power demand, shall be applied as follows:

Power Demand of Driven Machine Service Factor

Up to 5 kW 1.2

More than 5 kW 1.1

AC motors shall be capable of operating continuously under rated output conditions within the voltage variation range and / or frequency variation rage as specified in Chapter 6.3

Further, the motors shall be capable of maintaining stable operation when running at 70% nominal voltage for a period of 10 seconds. The pull-out torque for continuously loaded motors shall be at least 160% of the rated torque and for intermittently loaded motors at least 200% of the rated torque.

DC motors shall be capable of operating continuously under rated output conditions within the voltage variation range with a fixed brush setting for all loads. Unless otherwise approved, the speed drop between no-load and full-load shall not exceed 10% of no-load speed.

6.4.4 Starting AC motor with direct on-line starting shall be capable of being switched on without damage to an infinite busbar at 110% of the nominal voltage with an inherent residual voltage of 100% even in phase opposition. For starting the motors from the individual main and auxiliary busbars, a momentary voltage drop of 20% referred to nominal voltage should be taken into consideration. With 85% of the nominal voltage applied to the motor terminals, each motor shall be capable of accelerating its associated load to full speed with a minimum accelerating torque of 5% of full load torque.

The maximum starting currents (without any tolerance) shall not exceed the following values:

• 3 times rated current for AC motors rated above 50 kW

• 2 times of rated current for DC motors

Generally, all motors shall be able to withstand three cold starts per hour, equally spaced. In addition, each motor shall be capable of withstanding three successive starts with the motor initially at operating temperature or once every twenty minutes without detrimental heating.


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Motors for frequent automatic starting shall have an adequate rating. In the motor data sheet MDS the Contractor shall state the frequency of starts permitted in compliance with the motor design.

6.4.5 Windings and Insulation Class The insulation of all motors shall be of class F but maintain in operation the temperature limits of class B materials. It shall be suitable for operation in damp locations, for occasional contact with corrosive gases and vapors and for considerable fluctuations in temperature.

The stator winding shall be suitably braced to withstand the forces due to direct-on-line starting and transfer conditions as mentioned before. The winding envelopment and tails shall be non-hygroscopic. The stator winding shall withstand the maximum fault current for the period determined by the associated protective devices.

The rotor winding (if applicable) shall be designed to give trouble-free continuous service including repeated direct-on-line starting. The rotor shall be subjected to a 120% overspeed test for 2 minutes without showing any winding dislocation.

6.4.6 Ventilation and Type of Enclosure All non-submersible motors shall be of the totally enclosed fan-cooled type, protection class IP 54 according to IEC 60529. Cable termination points shall be of class IP55.

They shall have a closed internal cooling air circuit re-cooled by an external cooling air circuit drawn from the opposite side of the driving end.

Motors of IEC size 132 and above shall be equipped with automatically controlled heating elements for protection against internal condensation of moisture during stand-still periods. Such AC heater shall be suitably fixed inside the motor casing, the leads shall be led to a separate terminal box.

Where motors are installed outdoors, a weather-proof design shall be chosen. Motors installed outdoors and directly subjected to solar radiation shall be rated such as not to exceed a maximum metal temperature of 85°C. Where necessary, such motors shall be provided with sun shields.

Vertical motors shall be provided with a top cover to prevent the ingress of dirt, etc.

Submersible motors shall be of protection class IP 68 according IEC 60529.

6.4.7 Bearings

As far as possible, the motors shall have sealed ball or roller bearings lubricated for life. All motors requiring bearing lubrication shall be equipped with lubricators permitting greasing while the motor is running and preventing over-lubrication. The bearings shall be fitted with grease nipples permitting the use of a universal grease gun.

Vertical motors shall have approved thrust bearings.

Where sleeve bearings are being used, they shall be of the self or forced lubricating type. If forced lubrication is required, it shall be arranged common to both the motor


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and the driven machine and provisions shall be made to ensure lubrication during start-up and shut-down operations without the necessity to start an auxiliary lube oil pump. Self-lubricated bearings shall be equipped with an easily accessible oil reservoir with overflow pipe and oil collecting vessel.

The bearings shall be protected and sealed against dust penetration and oil leakage.

In case of independent bearings, motor and bearing pedestals shall be fitted on a common base plate.

For the transport of motors equipped with ball or roller bearings, special bearing inserts shall be provided to prevent transport damage.

6.4.8 Shafts and Couplings The motor shall be balanced together with the motor side coupling.

6.4.9 Brushgear and Commutators Brushgear for DC motors shall be designed to ensure constant brush pressure. Carbon brushes shall be provided which stand at least 6 months of operation without replacement. Each brush shall be independently adjustable but should not require adjustment throughout its life. A design of brushgear which permits the brush holder to touch the commutator as the brushes wear or which passes current through the pressure fingers will not be accepted.

A sufficient number of brushes, not less than two per pole, shall be fitted to ensure that vibrations do not affect the commutation.

The minimum safe wearing margin of commutators shall not be less than 20 % (twenty) of the total thickness of the commutator bars and the minimum safe diameter shall be clearly marked on it.

6.4.10 Terminal Boxes and Grounding

The terminals, terminal boxes and associated equipment shall be suitable for terminating the respective type of cables. The terminal boxes shall be of ample size to enable connections to be made in a satisfactory manner. Supports shall be provided at terminal boxes for proper guidance and fixing of the incoming cables.

The terminal boxes with the cables installed shall be suitable for connection to supply systems with the short-circuit current and the fault clearance time determined by the motor protective devices.

A permanently attached connection diagram shall be mounted inside the terminal box cover. If motors are provided for only one direction of rotation, this shall be clearly indicated.

Terminal boxes shall be totally enclosed and designed to prevent the ingress of moisture and dust. All joints shall be flanged with gaskets of neoprene or similar material. For motors above 1 kW, the terminal box shall be sealed from the internal air circuit of the motor.


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Depending on the size, the terminal box of motors shall be fitted either with an approved cable sealing-end or with a gland plate drilled as required and provided with suitable fittings for cable fixing and sealing. Such openings shall be temporarily plugged or sealed during transportation.

For grounding purposes, each motor shall have adequately sized bolts with self locking washers at the lower part of the frame. In addition, each terminal box shall contain one self locking grounding screw.

6.4.11 Measuring and Monitoring All motors above 50kW shall be provided with resistance temperature detectors embedded in the stator winding slots of each phase. The leads shall be brought out to the motor terminal box.

6.4.12 Vibrations In order to prevent undue and harmful vibrations, all motors shall be statically and dynamically balanced.

Vibration displacements or velocity shall be measured in accordance with DIN 45 665 for IEC motor sizes 80 to 315. The results for all motors shall be within the "R" (reduced) limits.

6.4.13 Tests Each motor shall be factory tested and shall undergo a test at site. The following tests shall be performed under full responsibility of the Contractor.

Workshop Tests:

Motors up to 50 kW

• Measurement of winding resistance

• Measurement of insulation resistance

• No-load measurements

Motors rated 50 kW and above

• Measurement of winding resistance


• No-load and short-circuit measurements

• Measurement of starting current and torque

• Efficiency measurement (type test)

• Heat test run (type test on motors rated 50 kW or higher)

Site Tests:


• Measurement of electrical values such as (starting) current, voltage


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• Measurement of motor vibrations (on motors rated 50 kW or higher)

• Measurement of starting time (on motors rated 50 kW or higher)

6.5 MV and LV Switchgear, Cubicles and Panels

6.5.1 General Design and Construction Features The electrical equipment delivered under this Contract shall be new and of high quality, suitable for the purpose it is intended for, free from defects and imperfections, and it shall be of the classifications listed herein, or their equivalents.

The equipment shall meet the applicable IEC Recommendations.

Electrical switchboards shall be constructed of braced rolled steel sections, with recessed panels, and supporting structures for mounting of power and control cables. All steel work shall be made sheet-steel having a minimum thickness as shown in the table below:

Item Min thickness [mm]

Panel rack 1,5mm

Doors 2,0 mm

Backplane 1,5 mm

Roof 1,5 mm

Mounting plate 3,0 mm

Floor plates 1,5 mm

Where required, (e.g. in case of heavy, flush-mounted equipment in a door) the thickness of the specific part has to be increased appropriately.

To avoid wobbling of doors, rear or side covers etc. they shall be adequately braced.

The cubicles shall be of robust and rigid construction, of the self-supporting floor mounted type. They shall be supplied complete with lifting lug eye bolts, with all necessary base frames, anchors, fixing materials, etc.

Where suitable, switchgear enclosures can also be of cast aluminum-alloy.

Cubicles mounted in rooms with subfloors shall have their own supporting structures made of steel profiles, being fixed to the concrete floor.

Wherever the correct operation of instruments and relays makes it necessary, adequate vibration and shock absorbers shall be installed.

All panels and cubicles shall be of standard dimensions, having a uniform appearance.

The switchgear shall be of the indoor, completely enclosed (protection class IP 42), metal-clad type with draw out or fixed mounted switching.


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The construction shall be such that the various compartments of the switchgear are segregated electrically from each other; it shall be possible to gain access to the circuit breaker and to the cable box chamber in any cubicle without having to take the busbars out of service. Hinged doors and bolted panels shall be provided.

The terminal blocks, relays and instruments shall be located so as to be safely accessible while the plant is in service. Suitable interlocks shall be provided for preventing access to live parts.

All instruments, control and selector switches, indicating lamps, push-buttons and trip buttons shall be flush-mounted and located at convenient heights on the front of the switchgear in a logical and clear manner. The layout of these panels is subject to the approval.

Cast resin insulators are permitted within individual cubicles but bushings entering or interconnecting different cubicles (for example busbars) shall be of absolute fire-resistant type (for example porcelain).

The design of the cubicles shall facilitate a possible extension at either end.

The cubicles shall have front access and - if not specified for erection at the wall - rear access for easy cable termination work and for maintenance and repair of the main and auxiliary equipment accommodated in the interior. Stopper shall be provided to limit the opening angle of doors to about 100°.

LV cubicles and panels shall be provided with interior lighting, controlled by door switches. LV cubicles shall be provided with an interior single phase power outlet which shall be protected by a residual current device.

The cubicles shall be complete with all locks, cable connection compartment, color coded busbars, internal wiring, terminal blocks and accessories.

Busbars shall be made of high conductivity electrolytic copper suitably protected against corrosion and rigidly supported on approved type of insulators.

Busbars shall be suitably mounted in enclosed compartments running the full length of the distribution boards. Access to the busbars shall be possible only by removing bolted covers.

Opening the back or front door of any circuit-breaker cubicle shall not expose the busbars. Busbar connections lying outside the busbar compartment shall be insulated or shrouded to eliminate hazardous accidental contact while working on other parts of the switchgear. Means to allow expansion and contraction of the busbars resulting from temperature variations shall be provided.

All busbar joints and connections shall be smoothed and silver-coated or tinned on the contact surfaces. If appropriate for the intended installation, contact surfaces can also be brightly polished and greased.

All switchgear, busbars and connections shall be capable of withstanding all electrical, mechanical and thermal stresses they may be subjected to, under normal or fault conditions.


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Clearances between live parts and to ground shall be in accordance with the relevant standards.

Each MV cubicle shall be provided with devices for grounding the incoming cables, preferably each phase separately. Provision shall also be made for grounding the busbars. Such grounding shall be interlocked with the incoming circuit breaker(s). Safety interlocks shall be provided to prevent grounding of live parts.

A grounding bar with a minimum cross-section of 40 x 6 mm shall run the full length of the distribution boards. This bar shall be connected to the main grounding system, and all metallic parts not forming part of the live circuits and all instrument transformer terminals to be grounded shall be connected to it.

Each MV cubicle/panel shall be equipped with a suitable mimic diagram.

All panels/cubicles shall have approx. 10% spare room for mounting of future auxiliary devices.

Water, steam or oil piping is not permitted in the cubicles.

Floor openings below cubicles shall be covered and sealed by the Contractor after laying of cables, etc., so as to obtain fireproof and vermin-proof installations.

Where required gland plates with suitable glands shall be provided.

Phase rotation and color markings shall be employed throughout the Works.

6.5.2 Switchgear/Motor Control Center (MCC) Feeders and Starters Circuit breakers, load break switches and motor starter units shall be of the removable or fixed mounted type. Where two or more starters or feeders are contained in the same cubicle, they are to be separated by barriers of sheet steel or fire proof insulating material. If required, the metal surface of the cubicle shall be protected by fireproof insulating material. The panels shall contain all respective starters and contactors with their main incoming and outgoing power feeders.

The draw out switching devices shall be mounted on trucks or slide in chassis having adequate guidance by greased sliding rails and/or rollers. They shall be connected to the busbars by means of a self-aligning plug and socket arrangements. Drawing out the switching device shall attain complete isolation of each circuit.

The main contacts shall have shutters, which automatically close upon withdrawal of the switchgear. The withdrawal of large circuit breakers shall be facilitated by means of cranks, gears or other facilities.

The contact surfaces of the plugs and sockets shall be silver-plated. The contacts shall be amply sized and sufficiently strong to withstand maximum short circuit currents and carry continuously the rated currents without damage or overheating of any kind.

The control circuits shall also be provided with plugs and sockets.

The removable units shall have clearly marked service, test and isolated (ready for complete removal) positions. A mechanical interlock shall be provided to prevent


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withdrawal of the unit unless the main circuit has been opened. The unit shall positively be locked in the test position before it is manually released for complete withdrawal. The test position shall permit local and remote closing and tripping of the relevant switchgear with the main contacts isolated from the power circuit.

Each switchgear room shall be furnished with a switching unit transportation carriage, the height of which shall be adjustable to the different installation heights.

All circuit breakers, load break switches, starters and contactors shall be suitably rated and controlled according to the electrical and mechanical performance and duties they are assigned for. Automatically controlled feeders (motor feeders, outgoing feeders) shall be equipped with a time delayed automatic tripping device operating in case of voltage failure at the busbars or being actuated by another defined signal.

All motor starters, contactors and their associated devices shall be capable of operating without overheating for a period of five minutes with a supply voltage of 70 % of the nominal value. Means shall be provided to prevent pumping.

Motor feeders shall be equipped as follows:

• HRC fuses with auxiliary contacts and load break switch, or

• Fused load break switch, or

• Circuit breaker with instantaneous over current protection

• Starter combination

• Adjustable thermal overload and phase failure protection

• Automatic motors starters as required.

Molded case circuit breakers and miniature circuit breakers can be used if they are properly selected to stand the maximum short-circuit current.

All starter and contactor units of the same rating shall be interchangeable. Remote controlled motor starters rated 5 kW and above shall include provisions for remote current indication.

Service hour meters shall be installed in the motor control centers if maintenance work such as re-greasing, oil change etc. depend on the operation time of the motors.

6.5.2.1 Circuit Breakers Circuit breakers shall be equipped with a driving mechanism composed of a spring loaded, energy storing closing and tripping device. Remote controlled circuit breakers shall be provided with an electric spring loading driving motor; manual spring loading and control shall also be possible. Means shall be provided to prevent pumping while the closing circuit remains energized should the breaker either fail to latch or be tripped during closing due to the operation of a protective device.

Barriers of approved heat resisting, non-tracking insulating material shall separate the CB phases.

The LV breakers shall be provided with main and isolating contacts, and with suitable arcing contacts, magnetic arc quenching devices, arc chutes.


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The spring release of the closing mechanism shall be affected by means of a DC solenoid coil and by means of a wing lever or mechanical push-in button. The closing mechanism can alternatively be of the AC solenoid coil operated and latched type.

Tripping shall be effected by means of DC solenoid trip coil and by means of a mechanical push-in button.

Large circuit breakers shall have a device to count the number of opening/closing operations.

The molded case circuit breakers shall have trip coil. They shall have a thermal overload of 125% of the normal full load current and instantaneous magnetic trips which operate at currents exceeding 500% of normal full load currents or 600% of motor full load current whichever is applicable.

Miniature circuit breakers shall be single-pole or triple-pole with adequate current ratings. The operating as well as the overload mechanism shall be sealed.

The contacts of control relays and of higher rated circuit breakers and contactors shall be silver-plated.

6.5.2.2 Contactors LV contactors shall be of the air break type with arc shields, class AC 3 according to IEC standards. All portions likely to suffer from arcing shall be easily removable.

When closed, the contactors shall withstand the system fault current determined by the next coordinated short circuit tripping device. The associated thermal overcurrent releases shall be adjustable in order to fit the motor requirements and be temperature compensated up to 70°C ambient temperature.

6.5.2.3 Fuses The HRC-fuses shall be suitably sized to cope with the connected loads at site conditions.

They shall be of the current limiting type and be of such characteristic as to correspond to the associated switchgear.

6.5.2.4 Load Break Switches The load break switches shall permit manual operation from the front panel. Where required they shall be designed to allow mounting of a remote control device.

They shall have a padlocking device and self-cleaning contacts with a high resisting anti-arc case and with quick-making and quick-breaking action, capable to switch the specified rated currents.

If suitable, the load break switches can be combined with the HRC-fuses.


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6.5.3 Switchgear/MCC Control For local switchboard control, all circuit breakers and motor-starter-contactor units, if applicable shall have:

• One (1) green-colored push-button for “OFF"

• One (1) red-colored push-button for “ON"

• One (1) position indicator of either the semaphore-type for circuit breaker, electrically controlled, or indicating lamps, included above.

• One (1) amber-colored indicating lamp for fault indication of local protection equipment (tripping of protection relay or device, blowing of power fuse, tripping of miniature circuit breaker of control circuits). This lamp shall remain lit until cancelled by resetting of the device having caused the fault indication. Facilities shall be provided to repeat the alarms, individually or group-wise for remote indication or recording.

Remote-controlled incoming and outgoing feeders as well as motor starters shall be equipped with key-operated LOCAL - REMOTE selector switches.

The “OFF" control shall be effective at all locations independent of the selector switch position while the “ON" control shall be restricted to the set selector switch position.

All manual operated Works shall have mechanical indications clearly indicating the relevant position.

Each bus section of a distribution board shall have a blue-colored signaling lamp indicating that the control supply is healthy, and each cubicle a yellow-colored signaling lamp-indicating heater “ON".

Indicating lamps shall be of an approved low consumption type. The hoods covering the lamps shall be made of transparent colored glass moulds or any other equivalent heat-resistant and break-proof material and shall be either of the screw or any other approved type to facilitate replacement of the lamps.

All indication lamp fittings of similar use shall be of the same size and type.

Where suitable, LED indicating devices are preferred to pilot lamps; they shall be of the multi-element type.

Lamp test facilities shall be provided on each panel. Up to 3 panels, forming an assembly can be fitted with one common lamp-testing device.

Individual panels or panel suites shall include indicating lamps for:

• Heaters on

• Control voltage

• Alarm/ trip

Generally the specified standard DC voltage(s) shall feed monitoring and protection circuits as well as trips of circuit breakers. All other circuits may be controlled by AC. Contactor-operating circuits shall be controlled by AC with the contactor solenoids


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preferably designed for DC, with pre-connected rectifier bridges. Where required, latched contactors shall be provided. Aforesaid circuits shall be protected individually by means of miniature circuit breakers with position monitoring. AC control circuits shall be derived from the relevant busbar system via supervised main fuses, isolating transformer and the above-mentioned individual MCB’s. Protection of trip circuits shall be coordinated with the suppliers of the protection system.

Closing of the circuit breakers and contactors shall be possible in the voltage range given in Chapter 6.3. Holding of contactors shall safely be affected at 70% of the rated control voltage. Tripping devices shall operate at 50 - 120% of the rated control voltage in case of mains dependent and at 75-115% in case of separate control voltages (DC system).

If applicable, for local control of motors, valves, drives etc., the following push-button shall be provided:

• One (1) Key operated selector switch having three positions; fixing the mode of operation of the drive with regard to the following criteria;

• 1st Position: “Off" (there is no access to that drive neither by the incorporated push button nor by the superposed control system).

• 2nd Position: “Local" means, the drive can be operated only by the incorporated ON/OFF push button. (Mainly used for tests and or maintenance purposes).

• 3rd Position: “Remote" The drive is controlled by the proposed control system only.

• One (1) “ON"- push button

• One (1) “OFF"- push button

• One (1) “Emergency OFF" - push button, which remains locked upon actuation and which can be released only by means of a special key. The effectiveness of this emergency push button shall not be restricted in any way. Its main function is the protection of personnel and Plant under emergency conditions.

6.5.4 Small Wiring All wiring within panels, racks, boards, etc. shall be of halogen free material insulated stranded copper wires.

The insulation material shall be of halogen free material, tropical grade. The wiring shall be capable of withstanding, without deterioration, the conditions prevailing at the individual location of installation. The bare ends of stranded wires shall be provided with squeezed sleeves or pins.

The minimum cross-section shall be as follows:

• 2.5 mm2 for all consumers (such as motors, heaters) and current transformer circuits

• 1.5 mm2 for control wiring above 60 V service voltage

• 0.5 mm2 for control wiring below 60 V and telephone wiring


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• About 0.2 mm2 in case the applied termination techniques of standard electronic equipment do not permit the use of larger cross-sections.

• In case of grounding on control wiring below 60 V, 1.5 mm2 shall be used.

All secondary wiring shall be arranged and protected to prevent it from being damaged by arcing or by mechanical effects.

Wiring shall be neatly run, bundled or in rigid halogen free material wire ways filled not more than 70%.

Wiring shall terminate in one or more terminal blocks, arranged at the side or bottom of each panel or compartment. Internal wiring between instruments or other devices not using the terminal block shall be permitted within the same compartment only.

Terminal blocks shall be numbered consecutively and shall consist of single insertion type terminals, non-inflammable synthetic material lined-up in one row. All terminals shall have two (2) separate pressure-clamping plates suitable for connection of incoming or outgoing, stranded and solid conductors, respectively. Terminals with clamping screws in direct contact with the conductor are not acceptable.

The following categories of terminals shall be provided and arranged as follows:

A. terminals for power circuits

B. terminals with short-circuit facilities for current transformer circuits

C. terminals for measuring, signal and control circuits, where required, with bridging facilities to the neighboring terminal

All category C terminal blocks shall contain 20% spare terminals. Insulating barriers shall be provided between each pair of power circuits and between the terminal categories. The height and the spacing shall be such as to give adequate protection to the terminals whilst allowing easy access to the same.

6.5.5 Marking of Equipment and Wiring All internal equipment and wiring shall be neatly and clearly marked as indicated on the schematic and wiring diagrams. Internal wiring and cables shall be marked with sleeve type engraved marking. Marking system and marking material shall be subject to approval by Employer. Identification of the respective conductors shall be in accordance with the requirements of ICEA/NEMA

6.5.6 Color Coding of Electrical Connections Live parts of electrical connections as well as cable conductors shall be color coded as follows

System / Part of Plant Phase Designation

Color of Conductor

Additional Conductor Identification ¹)

Remarks


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System / Part of Plant Phase Designation

Color of Conductor

Additional Conductor Identification ¹)

Remarks

Medium and High Voltage AC-Network:

*) Depends on the insulation of the cables respectively busbar

- Phase R L1 arbitrary *) 1)

- Phase S L2 arbitrary *) 1)

- Phase T L3 arbitrary *) 1)

- Protective grounded neutral

PEN green-yellow

Low Voltage AC-Network:

- Phase R L1 brown

- Phase S L2 black

- Phase T L3 grey

- Neutral N blue

- Protective grounded neutral

PEN green-yellow

220 VDC-Network:

- Positive + 220 V + red

- Negative - 220 V - blue

- switched plus arbitrary

110 VDC-Network:

- Positive + 110 V + red

- Negative - 110 V - blue


48 VDC-Network:

- Positive + 48 V + white

- Negative - 48 V - black


Current Transformer Circuits (K/L):

L1, L2, L3 black Imprinted numbers

Voltage Transformer Circuits:

- Phase R, S, T, Protective grounded Protective grounded neutral

L1, L2, L3 black Imprinted numbers

- Grounded neutral

N black Imprinted numbers

Control and Measurement Circuits, Auxiliary Circuits

black Imprinted numbers

1) The additional conductor identification shall be made by the use of cable shoes with colored collar of insulation material, identification collars, colored special tapes, etc.


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6.6 Instrument Transformers Current and voltage transformers are to be housed and designed to suit their particular duties. They shall meet the requirements of the latest relevant approved standards for metering and for protection and be capable of withstanding without any damage or deterioration:

• The continuous thermal current rating of the associated switchgear and

• The maximum short-circuit level of the circuit for a period of one (1) second.

All current transformers shall be capable of carrying rated primary current with an open-circuited secondary winding for one (1) minute without damage or deterioration.

Separate cores shall be provided for protection and metering circuits. The current and voltage transformers shall have adequate accuracy, saturation factor and rated burden. The Contractor shall determine the burdens and accuracy class of the secondary windings taking into consideration the most unfavorable conditions.

If no reference is made in the Particular Technical Specifications the secondary windings of instrument transformers shall have the following ratings:

• 1 A for current transformers

• 100 V for voltage transformers

The secondary windings shall be wired to suitable terminal boards and grounded at one point in the circuit.

The terminals of current transformers shall be provided with short-circuiter.

Switching of current transformer circuits is not permitted.

Voltage transformers shall be fused in both phases on the secondary side by means of miniature circuit breakers as close as practicable to the transformer terminals. The miniature circuit breakers shall be equipped with auxiliary contacts used for alarms, tripping and interlocking as required in the application.

All current and voltage transformers shall be provided with a plant label giving type, ratio, class, output, serial number and connections.

The Contractor shall supply manufacturer’s test certificates on tests and measurements to be performed in accordance with applicable standards. The current transformers and their associated circuits shall be tested at site by the primary injection method.

6.7 Protection Devices The main parts of the plant shall be protected and interlocked so as to prevent false-operations, other fault occurrences and to maintain safety during all operation phases.

Electric protection relays or protection systems shall be the standard product of an experienced protection relay manufacturer. They shall be of the static analogue or numerical type, suitable for tropical conditions and be mounted in suitable dust proof and shock-absorbing casings or panels. They shall not be affected by external magnetic fields or any other influence (radio, computer, signals, impulses, etc.).


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The protection relays or protection systems shall be equipped with all necessary auxiliaries such as tripping unit, time relay, external resetting device. The relays shall provide easy access for testing and setting purposes.

Pre-warning alarms shall be initiated as early as possible before the protection system trips, in order to enable the operators to take precautions. Tripping of a protection system as well as the sources of the protective action shall be indicated and recorded as an alarm.

Unless otherwise required for special purposes, protection relays shall remain in the tripped position until the operator resets the relay manually. The protection and auxiliary relays shall be grouped and mounted on plug-in modules or stationary-mounted on swing frame with separate plugs and sockets to feature easy replacement and testing. The construction shall be sturdy and such that all parts are easily accessible for adjustment. No protection relay shall be installed in MV cubicles except where approved. In this event they shall be arranged in compartments separated from the switchgear.

All relays shall have sufficient contacts and/or auxiliary relay contacts to perform all the tripping, inter-tripping, interlocking, indication and alarm functions required. Spare contacts (1 NO/1 NC.) shall be provided for later use. The relay contact rating shall be for the specified standard voltage and for 200% of the nominal passing current.

Testing of the individual relays shall either be effected by stationary-mounted or portable testing devices.

6.8 Auxiliary Equipment

6.8.1 Auxiliary Switches Where appropriate, each item of the plant shall be equipped with all necessary auxiliary switches, contactors and devices for indication, protection, metering, control, interlocking, supervision and other services. All auxiliary switches shall be wired up to terminal blocks on the fixed portion of the plant.

All auxiliary switches and mechanisms shall be mounted in approved accessible positions clear of the operating mechanism and are to be protected in an approved manner.

6.8.2 Control Switches Where applicable, control switches for electrically operated circuit breakers shall be of the discrepancy type. They shall operate clockwise when closing the circuit breakers and anti-clockwise when opening them. The control switches shall be so designed as to prevent them from being operated inadvertently, and where switches of the discrepancy type are used they shall require two independent movements to effect operation.

Switches for other apparatus shall be operated by shrouded push buttons or have handles of the spade type.


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Control, reversing, selector and test switches shall be so mounted, constructed and wired as to facilitate the maintenance of contacts without the necessity for disconnecting wiring.

6.8.3 Anti-Condensation Heaters Each individual enclosure accommodating electrical Works which is liable to suffer from internal condensation due to atmospheric or load variations shall be fitted with heating devices suitable for electrical operation at the specified standard AC voltage, being of sufficient capacity to raise the internal temperature by about 5°C above the ambient temperature. Heaters in motors and similar equipment shall be switched on automatically upon opening of the motor starter and vice-versa. Heaters in switchgear and / or MCC cubicles, control cubicles, panels, etc., shall be controlled automatically by adjustable hygrostats (setting range about 50 - 100% relative humidity). The electrical apparatus so protected shall be of such design that the maximum permitted temperature is not exceeded if the heaters are energized while the apparatus is in operation.

Heaters shall be equipped with a suitable terminal box. All equipment, whether fitted with a heating device or not, shall be provided with suitable drainage and be free from pockets in which moisture can collect.

6.8.4 Electrical Connections Bolted connections shall correspond to the applicable DIN Standards and have two washers and one spring washer. Bolt terminals of machines (motors, transformers, etc.) shall be equipped with secured nuts, two washers and spring washer, all the above elements being of corrosion-proof material or plated accordingly.

Tightening of such bolt connections shall be done with a torque wrench set to values to be given by the Contractor before commencement of erection work.

Busbar interconnection of individual units (switchgear/busducts/ transformers) shall be done by flexible joints. They shall be rated as per the respective busbars; the length shall ensure the flexibility against vibrations, thermal or operational displacements and also withstand the dynamic short circuit stresses.

6.9 Cables and Cable Laying

6.9.1 General The Contractor shall provide the relevant design and engineering of the relevant cable systems and in close co-operation with other concerned contractors, prepare the cable installation drawings with cable routing, connection diagrams, and cable lists, details, etc.

The Contractor shall select the most suitable cable routes and raceways ensuring a minimum of interference with other installations and other Lots.

The maximum continuous current carrying capacity of each individual cable type and cross-section used shall be determined, taking into account site conditions. The resulting load reduction factors are subject to approval.


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All cables shall be designed to cope with the short circuit conditions and the applied protective system.

Cable conductors shall be of annealed, high conductivity copper conductors lay up and rendered smooth and free from defects likely to injure the insulation. Under no circumstances cable through joints / mid joints will be accepted.

Cables running on or nearby hot surfaces shall be of the copper sheathed mineral insulated (MICC), silicon-rubber insulated, or other approved type.

All cables either running outside of buildings or directly laid in the ground, the whole or part of their length, shall be of the highest thermal and mechanical strength. They shall be single wire or tape armored.

All armored cables shall have an outer sheeting to prevent the armoring from corrosion. The armoring is also intended to avoid damages caused by rodents.

The identity of the manufacturer shall be provided throughout the length of the cable by embossing the outer sheath with “name of Manufacturer - year of manufacture“. The letters and numerals shall be raised and shall consist of upright block characters. The gap between the identification marks shall not be greater than 200 mm.

6.9.2 Standards Unless otherwise stated hereafter, ratings, characteristics, tests and test procedures etc. concerning the materials described in this section shall comply with the provisions and requirements of the IEC Publications each as they apply.

In order to minimize the required number of type of cables, all cables shall be standard-ized regarding their cross sectional area, number of strands and marking of strands.

6.9.3 Insulation Materials For insulation and sheathing only halogen free material according IEC 60754 shall be used.

All cables shall be at least flame retardant according to IEC Publication 60332.

6.9.4 Rated Voltages and Test Voltages

The rated voltage of the AC and DC power cables shall be 1/0.6 kV. The test voltages shall be as follows:

− Power frequency withstand voltage (factory test) 3.5 kV − Power frequency withstand voltage (site test) 2.0 kV

The rated voltage of the control, measuring and signal cables shall be 500/300 V. The test voltages shall be as follows:

− Power frequency withstand voltage (factory test) 2.0 kV


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6.9.5 Voltage Drops All power cables shall be dimensioned to stay below a 3 % voltage drop at nominal operating current. The voltage drop of all controlling, measuring and special cables shall be determined in each individual case, in order to assure correct service of all connected apparatus and instruments even under the most severe variations of the power sources.

6.9.6 Power Cables All cables shall be selected to withstand without damage the short-circuit current in conductors and armor. The minimum cross-section of the conductors, with due regard to a maximum allowable voltage drop shall be at least:

• 1.5 mm² for secondary power cables

• 2.5 mm² for main power cables (such as motors, sockets, heaters) and instrument voltage transformers

• 4 mm² for instrument current transformers

For cross-sections equal or larger than 120 mm2, single core cable shall be used.

The cross sectional area of the neutral and protective ground conductor in percentage of the phase conductor shall be as follows:

Phase conductor Neutral conductor PE conductor

1.5 – 16 mm2 100 % 100 %

> 16 mm2 50 % 50 %

Low voltage power cables shall be of the extruded solid dielectric insulated type.

Medium and high voltage power cables up to 275 kV shall be of the cross-linked polyethylene insulated type.

The XLPE cables shall be capable of continuous operation at a highest system voltage as specified with a maximum conductor temperature of 90°C, and a maximum temperature under fault conditions of 250°C.

All conductors shall have colored insulation according to the phase colors or, alternatively colored plastic sleeves can be used at all cable terminations.

6.9.7 Instrumentation, Control and Communication Cables

The control cables shall be of the stranded, multicore type.

Cables for analogue signals shall have a common screen of metal tape, cores shall be twisted pairs and concentric circular stranded (7 strands) conductor.

Communication cable shall have outer common screen of metal type, cores shall be twisted pairs individually screened.

The cross-sections shall be adequate for the design of the plant. In all cases, the maximum voltage drop on the cables shall not exceed 5% at the worst load and temperature conditions.


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The minimum cross-section of each core of the instrumentation, control and communication cables shall be as given below:

• 1.5 mm2 for all cables above 60 V service voltages

• 1.5 mm2 for all cables leading from the terminal boxes to individual local instruments

• 1.5 mm2 for all thermocouple compensation leads

• 0.5 mm2 for all multicore cables leading from local terminal boxes to the control room (if applicable).

Multicore cables with more than 7 cores shall have approx. 20% spare cores for future use.

Multicore cables shall be number-coded and/or color-coded or identified by other suitable means.

The color-coding or other identification system shall be shown on the circuit/connection diagrams.

6.9.8 Cable Laying

6.9.8.1 General All cables shall in principle be laid in one single length. If it is not practicable to lay the cables in one length, approved connections shall be used.

As appropriate for the various locations the cables shall be installed in cable ducts, raceways, conduits, tray systems, cable trenches or directly laid in the ground.

Cables running inside buildings or concrete trenches shall be laid on trays to be supplied by the Contractor who supplies the cables except where specified.

The trays shall be of adequate strength and size to carry the specified number of cables, providing approx. 25% spare capacity. The design of such trays shall include a safety factor to avoid permanent distortion when supporting erection staff during cable installation. The trays shall be of suitable aluminum alloys or hot-dip galvanized steel standard materials.

In chemically endangered areas all trays, supports, ladders, etc., shall be of hot-dip galvanized steel elements painted with suitable epoxy-resin paint or provided with a sintered coat of suitable material for protection against such chemical environment. Cable trays shall normally be of the ladder type consisting of bars with rungs, evenly spaced (max. 500 mm) according to requirements. Perforated, covered metal trays shall be used in highly polluted or otherwise endangered surroundings. All trays hall be rigidly fixed on supporting steel structures, masonry or galvanized racks. Cable trays arranged one above the other shall be at least 300 mm apart in case of power cables and 200 mm in case of control cables.

Cables laid on trays or racks shall be properly fixed or clamped. Supports and racks shall be arranged to facilitate removal or replacement of cables.


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Cables branched from general raceways and directed to the relevant equipment shall be suitably protected over their entire length by e.g. galvanized steel conduits sealed at their ends against ingress of water. Generally in industrial areas and machine rooms, the conduits shall be fixed on steel structures or on walls as required. In general control rooms and offices, for architectural reasons, the conduits shall be embedded or the cables shall be laid in approved surface mounted trunks.

Conduits embedded in concrete or block work shall be of suitable PVC-type. Cables lay outdoors, across roads in concrete or foundations shall run in hard PVC plastic pipes buried in the ground in a depth not less than 600 mm or embedded in concrete foundations at suitable depth.

The cross-section area of conduits shall be utilized to 60% only. Conduits shall terminate in concrete manholes before entering buildings. Manholes and pull-pits shall be provided where required to facilitate cable installation.

Cables on brick walls or similar civil structures can be laid in conduits (painted galvanized steel conduits within the reach of persons or erection/maintenance devices) or in prefabricated installation channels made of galvanized sheet metal or plastic.

Unarmed cables shall be properly protected against mechanical damage when leaving ducts or covered trench works and the like.

Cables directly buried in the ground shall be laid as follows:

• Cable trenches shall be excavated approx. 110 cm deep; the width shall be appropriate to the quantity of cables.

• Bottom of trenches shall be covered by a 10 cm layer of fine, clean material (preferably sand)

• Cables shall be laid on this layer of fine material

• Cables shall be covered by a 15 cm layer of fine, clean material (preferably sand)

• Cable protection tiles shall be laid along the cables

• Trench shall be carefully backfilled with excavation material approx. 20 cm high; the material shall be adequately compacted

• Colored plastic warning tape(s) shall be laid on top of this layer

• Trench shall be completely backfilled, material compacted and surface reinstated. Excess material shall be removed.

Except where specified, civil works for excavation and backfilling, are not included this Contract. However the Contractor shall supervise this particular grounding works and report to the Employer.

The Contractor shall provide in due course all required information on cable ducts, trenches, manholes, block-outs, foundations, etc. which shall be constructed by the civil contractor.

Minor civil works like slotting or chiseling shall be included in this Contract. A distance of approx. 30 cm shall be kept to other services.


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The Contractor shall be responsible for any damage caused by him to the buildings, and shall be responsible also for making good finishing of all buildings affected by his works.

The Contractor shall observe the following particulars for cable installation in concrete trenches:

• Cable trench covers shall be removed in sections, according to the progress of work.

• Removed covers shall be stored in such a way that they do not create a hazard to people or traffic at site.

• Cables laying in open trenches for more than two weeks shall be protected against sun radiation.

• Open trenches shall be properly secured by red warning tapes both sides along the trench.

• The Contractor shall replace any cover, cable or cable tray having been damaged during installation.

• Cable trenches shall be cleaned from dirt, sand, etc., before closing.

• Trenches shall be closed as soon as possible.

All works specified above shall be carried out by the Contractor.

6.9.8.2 Partition and Sealing Fire-partitions shall be provided when cables are passing through different fire zones or when entering cubicles and panels.

Cable passages into buildings shall be sealed fire-and waterproof.

Accessible cable galleries shall have fire-barriers at suitable spacing including normally open fire doors, which are closed automatically in case of fire.

6.9.8.3 Cable Arrangement Power and instrumentation / control cables must be run on separate cable trays, where this is not possible they must be separated by a minimum of 300 mm, subject to approval. Medium and high voltage cables of different systems shall be segregated in order to minimize mutual effects of short circuits.

Cable crossing in the same plane shall be avoided.

Special precaution shall be taken to ensure that no magnetic circuit is formed around single core cables laid in single or trefoil formation, or around any cable liable to carry unbalanced currents.

The pulling, and fixing and terminating of cables shall be strictly in accordance with the manufacturer’s instructions, using the recommended tools and appliances.


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6.9.9 Cable Termination For all terminations of wires and cables, the insulation shall be neatly stripped without nicking the strands of the conductors.

Cable lugs for power cables shall be of adequate size. Cable glands or clamps shall be fitted in all cases to prevent stresses on conductors or terminals. Fork type cable terminal ends will not be accepted.

The sealing compound and sleeves used in terminations has to suit the conditions under which the cable is to operate. MV and HV cable terminations will only be accepted if the insulation readings, 24 hours after making off, is higher than 100 MΩ.

Some slack cable in a loop or other suitable form is to be allowed at a convenient place in the runs where required.

6.9.10 Tests

6.9.10.1 Workshop tests All cables shall be tested in accordance with the Contractor’s detailed quality assurance program. The extent of thee factory test and the test methods shall be governed by the recommendations of the relevant IEC publications.

6.9.10.2 Site tests Power cables shall be tested as follows:

• Cable checking

• Continuity checking

• Insulation resistance measurement in accordance with the applicable codes and standards

• Measurement of voltage drop of critical lengths

• Dielectric test according to IEC 60502 (MW and HV cable only)

Control, instrumentation and communication cables shall be tested as follows:

• Cable checking

• Continuity checking

• Insulation resistance measurement in accordance with the applicable codes and standards

• Measurement of voltage drop of critical lengths

Fiber optic cables shall be tested as follows:

• Operational tests to verify correct operation of the optic system

• Connector attenuation tests to measure losses in all connectors in dB

• Transmission attenuation test to measure transmission losses in dB/km

• Reflection tests to find position and type of fault (crack or break) of the fiber


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• Speed tests to measure one-way propagation time.

6.10 Equipment Grounding The contractor shall design and install a grounding system for protection of persons and material to allow safe service and maintenance work on the installations.

The grounding system shall be designed to avoid dangerous touch or step voltage. The grounding conductors shall be dimensioned to carry without any damage the maximum ground current expected under fault conditions.

The dimensioning shall be coordinated with the protection devices of the various components of the plant. The conductors shall be bare E-copper that shall reliably be protected against mechanical damages and corrosion. Provisions shall be made to ensure a constant low ground resistance.

Each conductor shall have its own separate connection point. Pressed on closed shoes shall be used for connections to bars.

The Contractor shall connect all equipment included in the scope of supply of his Contract to the general grounding system of the plant. In addition to the grounding of cable screens, all equipment such as cubicles, motors, etc. shall be connected directly to the grounding system using copper wire. All metal parts such as steel liners, penstocks, supports, covers, railing, etc. shall be connected to the grounding system.

Shielding of control, instrumentation and communication cables are to be grounded at the cubicle end of the cable and not at the field device side.

6.11 Explosion-Proof Works

6.11.1 General

According to the kind of oils and fuels used, explosions in hazardous locations may be caused by standard type electrical Works. Therefore, the installations in such locations shall generally be kept to a minimum with said Works designed or installed in compliance with the latest issue of IEC Recommendation 60079 and the appropriate articles of the American National Electrical Code (NEC) or the German VDE Standards 0165, 0170 and 0171.

6.11.2 Definition of Hazardous Locations Hazardous locations shall be defined as follows:

A) locations are those:

(1) where hazardous concentrations of inflammable vapors or gases exist continuously, intermittently, periodically under normal conditions of operation and maintenance and with normal leakage, and

(2) where the breakdown or faulty operation of process equipment could release explosive concentrations of fuel and cause a simultaneous failure of electrical Works.


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B) are those:

(1) adjacent to locations indicated in paragraph A) which may occasionally be reached by hazardous concentrations, and

(2) where inflammable volatile liquids or gases are handled, processed, or used, but where concentrations are not normally hazardous because liquids or gases are handled in closed systems, and

(3) where hazardous concentration is normally prevented by positive ventilation. These locations become only hazardous when the ventilation systems fail.

6.11.3 Design Features The design features of electrical Works and/or circuits to reach explosion proof conditions shall be selected with due regard to the place of installation and the kind of Works.

The main features shall be as follows:

• Pressure and Flame-proof Enclosure

• All parts which may ignite a hazardous atmosphere shall have an enclosure of sufficient strength to withstand the maximum pressure caused by ignition of the most inflammable mixture of the gas involved. All necessary joints of such enclosure shall be provided with long fits (minimum 25 mm) and close clearances (equal or smaller 0.6 mm) to cool the escaping flame and to prevent flame propagation to the outside atmosphere.

• Oil Immersion:

• The parts capable of igniting inflammable or explosive mixture shall be immersed in oil to such an extent as to prevent ignition of explosive mixtures above the surface of oil by means of sparks or hot gases produced under oil.

• Increased Safety:

• To obtain an increased degree of safety on electrical Works, special measures shall be taken to prevent non-permissible high temperatures, sparks or arcs inside and outside of the Works on which they do not occur under normal working operations.

• Intrinsic Safety:

• An electrical circuit or part of such a circuit shall be considered as intrinsically safe if neither during normal working operation nor under fault conditions explosive mixtures are ignited by means of arcs, sparks, or any heat generation.

• Any other approved feature not mentioned above.

All explosion-proof Works shall be of approved design and must have undergone type tests according to the appropriate standards.

The selection of such Works with reference to design features and allocation to hazardous groups shall be subject to approval by the Employer.


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7 INSTRUMENTATION AND CONTROL EQUIPMENT (I&C)

7.1 Operation Levels

7.1.1 General The following operation levels shall be implemented:

• Operation Level 0: local distributed

• Operation Level 1: local centralized

• Operation Level 2: Plant

• Operation Level 3: Remote

At each operation level a local / remote selector switch shall be installed for the selection between the respective local operation level and the next higher level of the operation level hierarchy.

7.1.2 Operation Level 0 Operation Level 0 shall be the local distributed operation of each device of the plant. This operation level shall be operable independently of the control system. It shall be implemented with switches, pushbuttons or similar conventional electrical or mechanical devices.

Care shall be taken, that each and every component can be operated conventionally in case of an outage of the control system, especially also the synchronization, the generator brake, emergency shut off valve etc.

Only a limited basic interlocking implemented hardwired electrical or mechanical shall be foreseen on this operation level.

Operation level 0 is intended to be used only for test purposes and in emergency situations. It can be assumed that skilled operators only will make operations in this operation level.

The electrical protection of generators, main transformer, lines, bus bars etc. shall be active also in Operation Level 0. All trip signals must be hardwired to the respective trip coils.

The mechanical protection of turbine, generator and main transformers shall be implemented in such a way, that it is also active with the programmable controller controlling the respective device is out of service. The mechanical protection can be implemented either conventional, in a protection relay or in an independent programmable controller. If the mechanical protection is implemented in a


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programmable controller, this controller must be supervised by another controller operating independently from the first one.

All emergency pushbuttons shall be independent from the control system.

In case of a generating unit, the emergency shutdown sequence to standstill including application of the generator brakes on reaching the defined speed and, if applicable, closing of hydraulic shut-off devices shall be active independent from the control system,

7.1.3 Operation Level 1 Operation level 1 shall be implemented in the control system. A touch panel or similr device shall be the man.-machine interface. Each man-machine interface shall be connected to one of the programmable controllers and shall be mounted in the same panel as the respective controller.

Each device shall be operable from one of the man-machine interfaces. The interlocking shall be programmed in the programmable controller.

The communication between man-machine interface and the respective programmable controller shall work independent from the plant process network. Operation Level 1 shall be operable even in case of a breakdown of the plant process network.

7.1.4 Operation Level 2 Operation level 2 is the plant control level. The main components of the plant control level are the plant computers located in the control room, theit peripheric devices like printers, large screens etc and the plant control network connecting the plant computers with the programmable controllers distributed over the plant.

The plant computers shall be redundant making sure that one computer is operable also in case of a failure of the second one.

The plant network shall be structured in such a way that an interruption of the network cable connection on one place shall not affect the communication between the plant computers and the controllers.

A failure of one device connected to the network shall not have influence on the communication between the others.

For the network connections between the control room and the field fiber optic cables shall be used. The fiber optic cables shall have be mechanical protected and rodent resistant.

7.1.5 Operation Level 3 Operation Level 3 is the remote operation of the plant.


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7.2 Operation Modes

7.2.1 General The following operation modes shall be implemented in case of the unit control:

• Manual

• Step by Step

• Automatic

7.2.2 Manual Manual operation is the manual operation of a single field device using the appropriate conventional actuator or man-machine interface.

Manual operation mode shall be implemented at Operation Level 0 (by conventional means independent from the control system) and Operation Level 1 (within the control system).

For important devices which are not part of an automatic sequence (for instance circuit breakers, disconnecting switches and grounding switches of a high voltage switchyard, manual operation has also to be implemented at Operation Level 2 and if specified in the PTS at Operation Level 3.

7.2.3 Step by Step Step by Step operation mode is the operation of a predefined sequence between two operation states step by step. The operator has to release manually the next step after completion of the previous.

Step by Step operation mode shall be implemented at Operation level 1 and if specified in the PTS at Operation Level 2.

7.2.4 Automatic In automatic operation mode, the transition between predefined operation states (like from unit standstill to unit load operation in case of a generating unit or a feeder changeover in case of a low voltage distribution) is possible using preprogrammed sequences. The operator has to select the desired state and to activate the sequence which will then be performed automatically. Each step has to be supervised for timely completion. In case of a timeout, the sequence has to be cancelled and appropriate action has to be taken to bring the concerned part of the plant to a safe state.

Automatic operation mode has to be implemented at Operation Level 1 and Operation Level 2. The grade of implementation for Operation Level 3 has to be defined in the PTS.


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7.3 Design Criteria

7.3.1 General All I&C components shall be of an approved and reliable design. The highest extent of uniformity and interchangeability shall be reached. The design shall facilitate maintenance and repair of the components.

The Works shall be pre-assembled to the highest extent in the Contractor's or Sub-Contractor's workshop, e.g., shop welding of thermometer wells and other connections, wiring of boards, desks, etc., including internal wiring and installation of devices shall be carried out. Fragile instruments shall be removed for transportation to site.

All components shall be suitable for continuous operation under site conditions. Materials for instrumentation and control equipment, including piping material which is exposed to the measured media, shall be selected accordingly.

All components shall be compatible with other electrical, electronic and mechanical Works.

7.3.2 Sizes of Indicators, Recorders, etc. The meters, instruments and recorders shall be of standard size, to be selected to guarantee unique appearance of switchgears, control panels, control desks, etc. The front glasses shall be of the anti-glare type. The scales may be 90° type for local control panels but must be 270° type for control room instrumentation.

The indicating instruments and recorders shall have the following or similar sizes:

Indicators on local control panels, LV, MV and HV switchgears

72 x 72 mm or 96 x 96 mm

Indicators on vertical sections of control desks in control room and on rectifier or converter panels

96 x 96 mm

Indicators on horizontal parts of control desks in control room

48 x 48 mm

Indicators on control panels in control room 96 x 96


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When incorporated in mimic diagrams

Recorders 144 x 144 mm (for line and 6-point recorders)

Pressure gauges and other dial type instruments (local)

preferably 150 mm diameter

The control switches, adjusters, etc., on the panels and desks shall harmonize with the utilized indicator sizes.

7.3.3 Transmitter Racks and Piping Wherever practicable, transmitters for flow, pressure, etc., shall be installed in readily accessible positions in the proximity of the measuring point, free from vibration and protected against damage, moisture, dust, corrosive air, and great temperature changes.

The transmitters shall be grouped and assembled as far as practicable on local transmitter racks or in cubicles with glass or Plexiglas-front.

The connecting lines between the primary elements and the transmitters shall be installed inclined in order to ensure that no air pockets or water locks are created.

7.3.4 Special Local Conditions If the prevailing local conditions require special measures, the following shall be observed for the I&C equipment:

• All local indicators shall be of stainless steel

• All copper pipes shall be protected with an external plastic sheath

• All external bolts and screws shall be of non-corrosive material

• All secondary shut-off valves, balancing and drain/blow-off valves shall be of the non-corrosive type

• All metallic instrument piping shall be protected with corrosion protecting painting, or shall be of non-corrosive materials

• All I&C equipment exposed to sun shall be protected against direct sun radiation. This can be done by protection casings, sun shields, etc.

7.4 Measuring Systems

7.4.1 General The components shall quickly respond to any changes of the measured magnitudes. Measuring ranges of indicators, transducers, etc., shall be selected in such a way that the rated value of the measured magnitude covers approx. 75 % of the range.


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All local instruments shall, as far as practicable, be mounted vibration free to allow good reading. Wherever required, damping elements shall be used.

Related systems shall be grouped together in local panels.

All local indicating instruments and test connections shall be included in the respective Works as integrated parts. The scope of local indicating instruments and test connections shall enable the operator to properly survey the Works, and shall also allow to adequately carrying out all acceptance and other tests.

7.4.2 Flow Measurements The primary elements of flow meters shall be standard Venturi tubes, pilot tubes, standard orifices, inductive or ultrasonic type. Their design and performance shall be in accordance with applicable standards.

The design and arrangement of tapping points, piping and valves shall be in accordance with VDI/VDE rules 3512.

Arrangement: The arrangement of the throttling devices, the straight lengths upstream and downstream from the throttling device shall be in accordance with the said standards. Bends shall be at a sufficient distance upstream from the throttling device, particularly when large orifice ratios are used.

7.4.3 Temperature Measurements Resistance thermometers and thermocouples shall be equipped with water-proof connection heads. Thermometer arrangements shall be such that the connection heads do not become warmer than 80°C, and the measuring inserts are easily exchangeable.

The temperature sensors shall be selected in such a way to minimize the number of different spare inserts.

Resistance thermometers shall be used as far as possible. They shall be of type PT 100, four-wire system, coping with DIN 43760.

The use of dial-type contact thermometers shall be restricted to bearing metal and oil temperature measuring. In all other cases, thermocouples or resistance thermometers and electric contact modules (monitors) shall be used. Glass thermometers or similar will not be accepted as contact thermometers.

7.4.4 Pressure Measurements Pressure gauges shall be shock and vibration-proof (preferably by filling with glycerin) and shall be equipped with toothed wheels and toothed segments of the machined type. They shall completely be made of stainless steel.

Higher than rated pressure shall not deteriorate the pressure gauge or affect its calibration. The pressure gauges shall be equipped with a radial connecting stud, to allow the mounting on a gauge holder.

Pressure gauges with potentiometers will not be accepted for use as a pressure transmitter.


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Pressure gauges and transmitters for inflammable liquids shall have filled systems and the filling liquid shall be separated from the inflammable liquid by means of adequate isolating membranes.

Each gauge, pressure switch and transmitter for absolute or differential pressure shall be equipped with a pressure gauge isolating valve including a test connection of the screwed type M20 x 1.5 mm so that such device can be removed without any disturbance of the plant operation.

Pressure gauges and transmitters for pressures of 10 bar and above, shall not be directly mounted on the pressure tapping point. They shall be mounted apart from the tapping point on gauge holders or gauge boards. Whenever possible, pressure gauges and transmitters shall be groupwise combined on racks or consoles.

Pressure gauges for high pressures shall be equipped with a relieve valve for safety reasons in case of leaks (with a rubber reverse flow check).

In case of flowing substances, the measuring point shall be selected in locations of undisturbed flow.

If the pressure is pulsating, the devices concerned shall be connected via flexible tubes or other pulse-absorbing means.

In general, all pressure gauges, transmitters and pressure contacts shall easily be accessible for maintenance and supervision.

The design and arrangement of tapping points, piping and valves shall be in accordance with VDI/VDE rules 3512.

The scales shall have a diameter of 150 mm with black letters and figures on a white ground. The calibration shall be in accordance with chapter units.

The adjustment of the pointer shall be possible by means of an adjustment device without removing the pointer from its axle.

The high and low pressure connections of differential pressure gauges shall be marked accordingly.

All casings shall be dust and watertight and be made of stainless steel.

7.4.5 Level Measurements The liquid level measurements in reservoirs and tanks with atmospheric pressure shall be made by means of pressure transmitter of mercury-free type, by displacement-type transmitters or float-disc-transmitters. Level switches shall be of the externally mounted float or displacement operated type. The switch shall not have any packing gland and there shall be a minimum of moving parts.

7.4.6 Electrical Measurements Electrical instrument transformers are specified in Chapter 6.6 of this General Technical Specifications.


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Electrical measurement converter shall be of the 4-20 mA or ± 10 V type.

All Electrical instruments shall be of flush mounted design, dust and moisture-proof and fitted with non-reflecting glass. They shall comply in any respect with the requirements of IEC Publication 60051.

Except for instruments employed for Works performance tests all instruments shall have an accuracy class of 1.5.

AC ammeters and voltmeters shall have moving iron system for connection to the secondary side of instrument transformers. DC measuring instruments shall have moving coil systems of the same accuracy. Wattmeters shall have electro-dynamic measuring mechanisms or alternatively a moving coil mechanism if fed by transmitters. Wattmeters shall be suitable for unbalanced systems.

All indicating instruments shall generally withstand without damage a continuous overload of 20% referred to the rated output value of the corresponding instrument transformers. Ammeters shall not be damaged by fault-currents within the rating and fault duration time of the associated switchgear via the primaries of their corresponding instrument transformers.

All instruments and apparatus shall be capable of carrying their full load currents without undue heating. All instruments and apparatus shall be rear connected, and the enclosures shall be grounded. Means shall be provided for zero adjustment of instruments without dismantling.

All voltage circuits to instruments shall be protected by MCB's in both phases of the circuit, installed as close as practicable to the main connection. All power factor indicators shall have the star point of their current coils brought out to a separate terminal which shall be connected to the star point of the current transformer secondary windings.

When more than one measured value is indicated on the same instrument, a measuring point selector switch shall be provided next to the instrument and shall be engraved with a legend specifying each selected measuring point.

Current transformer connected Ammeters provided for indication of motor currents shall be provided with suppressed overload scales of 2 times full scale. The dials of such ammeters shall include a red mark to indicate the full load current of the motor.

Instrument scales shall be submitted for approval by the Employer. All instruments mounted on the same panel shall be of same style and appearance.

All metering circuits shall be terminated in marked terminal blocks for remote metering purposes.

7.4.7 Position Measurements

Position transmitters of the potentiometer type will not be accepted. Inductive or capacitive type shall be provided.

Position transmitters for continuous position indication and measuring transducers shall be of the 2-wire type and shall have an output current of 4-20 mA (± 10 V resp.).


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7.4.8 Limit Switches Limit switches shall be provided for all electrically operated devices such us gates, valves, gantries, etc. to automatically stop the motor at both ends of travel. Additional switches shall be provided where necessary for control, interlocks and indication.

Limit switches shall be mounted suitable for easy adjustment and for rigidly locking in position after being adjusted. They shall be of heavy-duty rating and have two changeover contacts suitable for specified control voltage level.

Switch fixings shall be unaffected by vibration. At the same time they should be capable of easy adjustment to suit changing parameters of the associated plant.

Particular attention shall be paid to potentially harmful environmental conditions, including water, oil, dust, dirt, temperature variations and differential expansions. Where switches operate through linkages, precautions shall be taken to eliminate variations of settings and incorrect operations resulting from wear or tolerances.

7.4.9 Contact Devices Contacts of level switches, pressure switches, temperature switches, limit switches, and of all other devices shall be of the snap-action type (SPDT). Contact devices for interlocking systems shall be separate, i.e., contact devices serving commonly for interlocking and other purposes will not be accepted.

7.4.10 Vibration measurement The measuring equipment has to comply with requirements stated in IEC 60994 and ISO 10817-1.

7.5 Interlocking and Lockout System The Interlocking and Lockout Systems shall be provided for all Works components and individual systems to ensure a safe and reliable Works operation and to limit harm and damage to personnel and Works to an utmost extent.

These devices shall facilitate the duty of the operating staff and prevent incorrect operation.

7.6 Tests The single components and pre-erected assemblies shall undergo functional and routine tests in the Contractor's or Sub-Contractor's workshop. The ready mounted control and supervisory system shall undergo functional tests on Site prior to commissioning of the Works.

Calibration tests shall be made on all important instruments and measurement devices as required by the Employer.


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8 TRANSPORT AND INSTALLATION

8.1 General For shipping, loading, transportation, unloading, and storage appropriate period shall be considered.

The delivery dates, transportation and erection periods indicated in the Contract Documents shall be strictly adhered to. Changes which are unavoidable or necessary will be regulated in accordance with the stipulations laid down in the General Commercial conditions of contract.

The Contractor shall provide the Employer with complete packing lists of each performed shipment.

8.2 Packing The Contractor shall prepare all plant, devices and materials for shipment to protect them from damage in transit, and shall be responsible for and make good all damages due to improper preparations, loading or shipment.

After the workshop assembly and prior to dismantling for shipment to the Site, all items shall be carefully marked to facilitate site erection. Wherever applicable, these markings shall be punched or painted so they are clearly visible.

Dismantling shall be done into convenient sections, so that the weights and sizes are suitable for transport to Site and for handling on the Site under the special conditions of the Project.

All individual pieces shall be marked with the correct designation shown on the Contractor's detailed drawings and other documents (packing lists, spare part lists, in Operating and Maintenance Instructions, etc.).

Marking shall be done either by labeling or by punching the marks into the metal before painting, galvanizing, etc., and shall be clearly legible after painting, galvanizing etc.

All parts of the Works shall be packed at the place of manufacture; the packing shall be suitable for shipment by sea and for all special requirements of the transportation to Site. Enough strong containers, cases or boxes shall be used in order to prevent damage and corrosion during transportation, unloading, reloading or during intermediate storage.

All identical members shall be packed together, if reasonably possible, in a form convenient for shipment and handling.

Small items shall be packed in boxes and large items shall be protected, where necessary, by timber, straw and sacking. All bolts, nuts, washers, etc. shall be packed in containers. Each container shall include only bolts, nuts or washers of identical size.

All parts shall be suitably protected against corrosion, water, sand, heat, atmospheric conditions, shocks, impact, vibrations, etc.


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All electrical parts shall be carefully protected from damage by sand, moisture, heat or humid atmospheric conditions by packing them in high pressure polyethylene foil. Where parts may be affected by vibration, they shall be carefully protected and packed to ensure that no damage will occur while they are being transported and handled.

The Employer reserves the right to inspect and approve the packing before the items are dispatched but the Contractor shall be entirely responsible for ensuring that the packing is suitable for transit and such inspection will not exonerate the Contractor from any loss or damage due to faulty packing.

All packing costs are part of the scope of work.

8.3 Marking The Contractor shall mark all containers with the implementing document number pertinent to the shipment. Each shipping container shall also be clearly marked on at least two sides as follows:

Consignee : XXXXX

Contract No. : XXXXX

Port of destination : XXXXX

Item number (if applicable), Package number, in sequence and quantity per package

: XXXXX

Description of Works : XXXXX

Net and gross weight, volume : XXXXX

8.4 Transport and Storage The Contractor shall inform himself fully as to all relevant transport facilities and requirements, loading gauges and other limitations and shall ensure that the equipment as prepared for transport shall conform to such limitations. The Contractor shall also be responsible for obtaining from the local railway or highway authorities any permit that may be required for the transport of loads exceeding the normal gauges.

The Contractor shall provide means for all unloading and reloading for all consignments of plant, both during transport to Site and on the Site. Consignments shall be unloaded immediately on arrival at Site. The Contractor is required to take the necessary steps in order to provide the carriage, special supporting structures for heavy loads, etc.

All parts of the plant shall be brought, as far as possible, to their final place of erection. The Contractor shall construct its own storage facilities at site.

The warehouse shall be weatherproof, with good ventilation and solid floors. The floors of the storage areas shall be designed to carry the loads imposed on them by the stored parts. The following parts shall be stored indoors:


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Bolts, pins, packing, tools, insulation materials, electrical parts with electrical devices attached, electric motors and excitation equipment, instruments, welding material and equipment, all small parts and all parts of the plant which already have been finally painted.

If large (mechanical) parts are stored in the open air, they shall be provided with weather resistant and fire-resistant covers. Electrical parts which are not packed in heavy duty polyethylene foil and those so packed but whose packing has been damaged shall be kept in suitable indoor places from the moment of storage up to the starting of installation.

All insulation materials which will be taken from the storage for installation and which are stored temporarily in the station shall be protected from weather and humidity.

All the equipment shall be stored as per standard storage and preservation instructions etc. of the suppliers.

8.5 Preparation and Installation Prior to commencement of installation, the Contractor shall closely inspect the site and all the foundations and other structures on which parts of the plant supplied under this Contract will be installed; he shall check that the foundations conform to the installation drawings.

The result of this check shall be reported to the Employer in due time to allow any errors to be corrected before the commencement of erection. All parts of the plant shall be cleaned carefully of all contamination such as dust, sand, rust, mill scale and other dirt prior to installation.

8.6 Reference Points The Employer will provide major center lines and datum levels only. The Contractor shall be responsible for transferring those required to carry out the Works. The Contractor shall employ a competent surveyor for setting-out of all datum lines including the constant checking and maintenance of the setting-out until the completion of his works.

The Contractor shall provide all necessary pegs, profiled templates and center lines and shall establish all such permanent markings and recovery marks as may be required by the Employer for checking the Contractor's setting-out. The Contractor shall be responsible for rectifying, at his own cost, all work rejected by the Employer due to errors in setting-out.

All bench marks, notch marks, pegs and signals on the surface, alignment pins and the like put in by the Employer for the purpose of checking the Contractor's work or as permanent survey marks will be under the care of the Contractor during the period of the Contract. He shall, at his own expense, take all proper and reasonable care and precautions to preserve and maintain them in their true position where such marks are within or adjacent to his work area. In the event of their being disturbed or obliterated by any cause whatsoever, they may, if so determined by the Employer, be replaced by the Employer at the Contractor's expense.


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The Contractor shall be responsible for the true and proper staking-out of the works and levels of reference given by the Employer in writing, for the correctness of the positions, levels, dimensions and alignment of all parts of the works and for the provision of all necessary instruments, appliances and labor in connection with this.

The checking of any staking-out or of any line or level by the Employer shall not in any way relieve the Contractor of his responsibility for its correctness.

8.7 Installation Works All transportation and handling of the plant from the place of storage to the place of installation shall be carried out by the Contractor. He shall provide all hoisting equipment, staging and scaffolding, winches and wire ropes, slings, tackles and all other appliances and temporary materials. The erection staging and scaffolding shall be provided with coverings and barriers and shall guarantee safe working conditions.

The Contractor shall comply with all applicable and approved safety regulations while carrying out the works on Site and with all reasonable requirements of the Employer. This stipulation shall in no way release the Contractor from any obligation concerning his liability for accidents and damages. He shall be responsible for adequate protection of persons, plant and materials against injuries and damages resulting from his operations.

The plant or parts to be installed shall not be overstressed during the process of installation.

The Contractor shall be responsible that the installation of all plant is properly executed to the correct lines and levels and in accordance with the manufacturer's instructions and the Contract requirements.

The alignment of the plant shall be done in accordance with the tolerances indicated by the Manufacturers, drawings or given by standards.

Setting of parts to be aligned shall be performed by means of fine measuring instruments. All erection clearances and settings shall be recorded. Copies of these records shall be given to the Employer. After alignment, the parts shall be held firmly in position by means of set pins, fitted bolts, etc.

Anchor bolts, baseplates, anchor rails, etc. to be embedded in the first stage concrete shall be delivered in due time with instructions and/or templates to facilitate the bringing in of such parts into the Civil works.

All parts to be embedded in concrete shall be set accurately in position and shall be supported rigidly to prevent displacement during the placing of concrete. Adjusting screws and bolts shall be drawn tight and secured adequately. Steel wedges shall be secured by welding. Wooden wedges shall not be used.

The Contractor shall verify carefully the position of all parts to be embedded before concrete is poured. All important measurements and dimensions shall be recorded. Copies of these records shall be given to the Employer for checking and approval before items are built-in to the Works.


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The Contractor shall be responsible for the supervision of the building-in work. He shall state the allowable concreting or grouting rates and any required sequence for pouring in the different places. After concreting, the control measurements shall be verified again, indicated in the above mentioned records and submitted to the Employer.

Any error in shop work which prevents the proper assembling and fitting of the parts shall be immediately called to the attention of the Employer and approval obtained for the correction procedures.

The Contractor shall provide all necessary anchors and braces to ensure the alignment and stability of the parts to be installed. All temporary anchors and bracings shall take care of all dead load, wind load, seismic and erection stresses, e.g., during concreting, and shall remain in place until they can be removed without endangering the stability of the plant.

If for installation purposes auxiliary structures have been attached to the plant, they shall be removed after completion of work and the surface restored to proper condition by grinding and repainting.

Special care shall be taken not to damage surfaces of galvanized or specially treated plant during erection. Care shall be taken to prevent or remove any rust streaks or foreign matters deposited on galvanized or otherwise finished surfaces during storage or transport or after installation.

Glass parts or other parts which can easily be damaged shall be provided with suit-able protective sheaths or coverings during installation.

Machined or bare metal surfaces which are to receive no coat of paint shall be protected during transportation, storage and erection by a suitable anti-corrosion film.

All power tools preferably are operated pneumatically. They are to be handed over at the end of the installation work in good condition in accordance with the Employer's instructions.

After erection, the works shall be finally painted, in accordance with the painting specification, and any damaged paintwork shall be restored.

The Contractor shall keep the site in clean condition during erection and commissioning time. On instruction of the Employer he shall remove waste from the place of installation to the defined deposit site at his own cost.

8.8 Civil Site Work

The following works shall be carried out as part of the civil works contract and is not included within the scope of work covered by the Particular Technical Specifications:

• All concrete work, including reinforcement and formwork, and all grouting required for filling in, around and under the various parts of the works to be embedded in concrete.

• All necessary excavation and backfilling required for installing the plant in its final position, unless otherwise stated in the Particular Technical Specifications.


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• Building in of all required parts into the first stage concrete. The readiness of such parts shall be communicated to the Employer and they shall be delivered in due time by the Contractor unless otherwise specified or agreed in the Contract.

• Providing and grouting the blockouts for all anchoring and foundation bolts needed to support and fix the plant in its final position.

• All protective measures, e.g., pumping, etc., to keep the various parts of the plant and the erection site free from water during the time of erection.

• Provision of cable and pipe ducts, trenches, block-outs, etc., in accordance with the drawings supplied by the Contractor and supervised by the Contractor.

• Adequate safety covers and protective measures against injury or damage to the Contractor's employees and equipment and to the works due to any operations of the civil contractor.

• If checkered plates or other covers provided under the civil contract require special care for fitting to plant and installations, such work (cutting, matching, welding of supports, etc.) shall be performed by the civil contractor.

8.9 Safety Precautions Prior to starting any work the Employer through the civil work contractor shall supply and fix in suitable positions near the work concerned large multilingual temporary signs and markings written in local language(s) designated by the Employer and in English giving clear warning of danger in areas which might previously have been regarded as safe.

The Employer through the Package 1 contractor shall provide all temporary scaffolding, ladders, platforms with the boards and handrails essential for safe and convenient access to the working areas by workmen, inspectors and other authorized persons employed for the Works.

All dangerous openings or holes in floors shall be provided with handrails or covers. Preventive measures shall be taken to protect workmen from falling material.

The maximum possible safety shall be afforded to personnel directly engaged on this Contract, those who frequent the working area or those who in the normal course of their occupation find it necessary to utilize temporary works erected by the Employer through the civil work contractor.

Working on energized electrical equipment is prohibited.

8.10 Fire Protection and Fire Fighting The Contractor shall be responsible for the fire protection of his buildings, working areas and storage rooms by providing trained personnel and fire fighting equipment.

Sufficient fire fighting equipment shall be provided on the Site for the full period from the commencement of site works until take-over of the Works.

The Contractor shall ensure that both he and his Subcontractors take all precautions to prevent fires occurring. In particular the following fire prevention measures shall be taken:


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No open fires shall be allowed within the site area. Burning of condemned materials shall be carried out in a specially designated area outside of the site area.

Combustible material shall be stored in places where spreading of fire is limited to a minimum. Non-combustible plastic foils shall be used for protection of material.

All combustible material shall be removed from working areas where the work going on requires the use of or produces open flames (e.g. welding). If such removal is impossible, the working area shall be specially protected by suitable fire fighting equipment.

The Contractor shall maintain the fire fighting equipment fully operational at all times and shall recharge extinguishers after use regardless of by whom they were discharged. Adequate stocks of fresh chemical charges for use in extinguishers shall be kept in readiness on the Site.

The Contractor shall nominate certain of his employees who shall be made available for initial training in fire fighting duties and subsequently for fire fighting drill and servicing of fire fighting equipment. The nominated employees shall be available for fire fighting duties at all times when they are on the Site.

8.11 Cleaning Up Throughout the duration of the Contract the Contractor shall maintain the Works in a clean and tidy condition.

All material not in use and/or no longer required for the Works, all condemned materials and all rubbish shall be removed from the Site, combustible rubbish shall be removed daily.

Upon completion of the Works, the Contractor shall remove all Temporary Works which he may have constructed for the protection of plant or his convenience while carrying out the works and all equipment and surplus materials and any remaining rubbish which may have accumulated in the execution of the Contract and shall leave the whole area in a clean and tidy condition.


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9 INSPECTIONS AND TESTS

9.1 General All equipment, including all materials, components, apparatus, etc. called for in these Specifications while in the process of manufacture and during installation and commissioning will be subject to such tests and inspections as required by pertinent standards, as may be the standard practice of the manufacturer and as deemed necessary by the Employer to prove compliance with the requirements of these Specifications.

Approval of assemblies, tests, inspections, related procedures, etc. shall in no way relieve the Contractor of his contractual obligations for furnishing the Works in accordance with the provisions of these Specifications.

The Contractor shall be responsible for the execution of all inspections and tests required to demonstrate during manufacture and on completion that the equipment complies with the requirements of the Specifications. The cost associated with all such inspections, checks and tests shall be borne by the Contractor.

The Contractor shall prepare an inspection and test program including all tests during and after manufacture (except for stock material) which shall form part of the Contract and which shall describe the inspections and tests for each major component and item. The program shall include a sufficiently detailed manufacturing schedule with all expected dates of inspections and tests, a description of each inspection or test (including the test method) to be performed and the applicable standards. Where Contractor's acceptance standards are proposed, copies of same shall be provided for the Employer's approval.

The inspection and test program and the related schedule shall be up-dated by the Contractor at two month intervals with clear indication of revised inspection and test dates.

Written notice of the exact date, time and place of inspections and tests to be attended by the Employer, as well as all other necessary information shall be given to the Employer in writing not later than 14 days prior to the date of any such inspections and tests.

Free and unrestricted access to the Contractor's factory and shops (including those of his Subcontractors) shall be granted to the Employer upon reasonable notice at all times.

Should an agreed inspection not be feasible as proposed due to lack of preparation, negligence or material and/or equipment being presented in a state which is clearly not acceptable, all costs incurred for the Employer and/or his delegate(s) for repeated inspections shall be fully borne by the Contractor.

9.2 Test Certificates Test records, test certificates, performance curves, tables, etc. of all inspections and tests, whether or not attended by the Employer, shall be supplied as soon as practicable after performance of each inspection or test. After completion of all testing the above-mentioned documents shall be supplied properly bound in books.


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All test certificates shall be endorsed with sufficient information for identification of the equipment and material to which the certificates refer. In addition, the following references shall be entered in the top right hand corner:

• Employer's name

• Project name

• Equipment designation (e.g. Governing System)

• Related Contractor's drawings (No.)

• Date of test

• Certificate issue date

9.3 Testing Inspection and testing of the equipment shall comprise, but not be limited to:

• Mechanical and chemical testing of materials

• Destructive and non-destructive tests of materials

• Checks and examinations of welds

• Checks of fits and assemblies

• Dimensional checks

• Inspection of paints and coatings

• Hydrostatic pressure and tightness tests

• Balancing tests

• Electrical tests

• Running tests (including measurements of vibration and noise)

• Functional tests

• Pressure and Leakage Test

• Performance tests

• Load and overload tests

• Load rejection and load taking-up tests

• Acceptance tests

These tests will be carried out principally as defined in the inspection and test plan.

The techniques, equipment and instrumentation to be used for these tests, checks, inspections, examinations, etc. shall be in accordance with internationally accepted standards, rules or codes, and in particular those mentioned in these Specifications.

If the Employer should justify that the instruments, apparatus, devices, etc. used by the Contractor (or his Subcontractor) require re-calibration, he has the right to request this to be done at the Contractor's cost.

(1) Random Sample Tests


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Random tests shall be carried out on random samples of a lot of equipment, parts or material. Selection of samples to be tested will be done by the Employer and all the equipment, parts, etc. shall be presented for this purpose. The number of samples taken will be either at the discretion of the Employer, particularly for smaller lots, or shall conform to the generally accepted rules and standards of statistical testing.

Should a single sample fail during random sample testing then the following shall apply:

a) Small lots: all pieces shall be fully tested

b) Large lots: a second set of samples, identical in number with the first one, shall be chosen and tested. If this set passes all tests satisfactorily, the lot shall be considered to be acceptable. If again one or more samples fail in one or more tests either the whole lot shall be rejected or all pieces of the lot shall be fully tested individually, as determined by the Employer.

Pieces of lots which have been declared unacceptable and samples which have failed in test shall be marked immediately and shall not be presented for test again.

(2) Non-Destructive Testing

Radiographic, ultrasonic, magnetic particle or liquid penetrating tests shall be conducted on components as appropriate. Where ultrasonic or magnetic particle tests indicate the possibility of a flaw, the suspect part shall be tested by radiography. All flaws shall be removed by thermal or mechanical gauging processes and replaced by welding. The replacement weld and contiguous parts of the original weld if any shall then be tested radiographic method. All radiographs shall become the property of the Employer.

9.4 Tests at Manufacturer's Works

9.4.1 General Before any material, equipment, apparatus, component etc. is packed or dispatched from the Contractor's or his Subcontractor's works all tests, inspections, checks, examinations, etc. required by pertinent and internationally accepted standards, rules or codes shall be carried out as far as practicable and agreed in same parties' premises.

All materials, apparatus and other parts or components of the equipment to be tested, inspected, checked, examined, etc. at the Contractor's or his Subcontractor's works shall be made properly accessible for testing and inspection work. There shall be no interference or disturbance from other shop activities when conducting checks, tests and inspections.

All equipment, materials, apparatus and other parts or components shall be adequately sheltered and protected against the weather whilst being tested, inspected, checked and examined.

Parts and components shall be assembled to the greatest extent possible and as agreed, and dimensional checks performed on all major assemblies, sub-assemblies, parts and components especially when close tolerances and fits are involved (tolerance of shafts, clearance between stationary and moving parts, connecting dimensions for assembly with other elements and supplies, combined functioning of electrical equipment, etc.).


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Components and parts to be weld-assembled at the Site shall be tag-welded in the shops to permit visual and dimensional checks of the fits and transitions. All such components and parts shall be match-marked properly to ensure correct assembly and welding at the Site.

If dimensional checks show discrepancies in measurements which may affect the fit, assembly or dismantling of the respective part or component, proper and workmanlike corrections or modifications shall, however, in no way lead to sacrifices with respect to reliability of operation or interchangeability and shall only be performed with the Employer's approval. If the correction or modification cannot be carried out in accordance with the terms mentioned above, the part or component concerned may be rejected.

Shop testing shall also include functional tests on partial or complete assemblies to the greatest extent possible and as agreed. Such tests shall, as far as possible, be performed under conditions as similar as possible to final operating conditions. When requested by the Employer the functional tests shall be repeated or extended until proof has been obtained that the assemblies will function in accordance with the Specifications.

Cubicles, cabinets and control boards shall, prior to their inspection and testing, be completely and properly assembled, equipped and wired internally in the Contractor's or his Subcontractor's shops.

9.4.2 Type Tests Type tests shall be performed to establish the required main characteristics of the equipment and that they conform to the requirements stipulated in the Specifications. Type testing shall be carried out on a single item of apparatus or assembly of each type and rating by a reputable testing institution and shall be witnessed and duly authenticated by an internationally known independent body or by the Employer. If there is evidence of successfully performed type tests on identical apparatus in an independent laboratory, the respective certificates may be accepted in lieu of testing. Such type test certificates shall be submitted to the Employer.

9.4.3 Routine Tests Routine tests are required on all equipment items both to prove that the product is in accordance with equipment which has been successfully type tested and to reveal faults or defects in materials or on equipment due to inadequate or insufficient supervision during fabrication, assembly, etc.

9.5 Tests on Completion Equipment will be subjected to site testing during and after installation work at the Site. Site tests shall comprise but not be limited to the testing, checking, inspection and examination of all equipment assembled, welded and set up at the Site. The period of site-testing and site-checking will be up to the Employers taking over of the Works.

The Contractor shall provide at his cost sufficient competent personnel (including those of his Subcontractors) as well as all equipment, materials and other services required for the proper and complete testing and putting into commercial service of all equipment. If in the opinion of the Employer the personnel are inadequate the Contractor shall at the


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Employer's request and at no additional cost provide additional, appropriately competent personnel.

Unless waived in writing all tests and checks shall be performed in the presence of the Employer. If not satisfied with the performance or results of the tests and checks the Employer shall have the power to ask for additional tests or repetition of the same.

9.6 Reliability Run Immediately upon termination of the tests on completion of a section of the Works which can operate as an independent unit or termination of complete Works, a reliability run shall be started. The duration and further details of the reliability run is stated in Commercial conditions of contract.

During the reliability run, the Works shall be subjected to normal operation with the generating units connected to the network for power supply at various loads and as required. The reliability and readiness for permanent use of the Works shall be demonstrated by this operation. The Contractor shall make the Employer's personnel familiar with the properties, the operation and maintenance of the Works to such extent that after completion of the reliability run the duties can be assigned to the Employer's trained personnel.

Should any defects be revealed during the trial operation which, in the opinion of the Employer, shows that the reliability and readiness for permanent use or other contractual requirements are not fulfilled, then the reliability run will be cancelled and repeated when the defects have been corrected.


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10 STAFF TRAINING To facilitate the reliable plant operation and maintenance after taking-over by the Employer, the responsible Employer's staff shall be made familiar with all equipment supplied by the Contractor and installed in the Plant. To reach this the concerned staff shall be properly trained during the manufacturing of the equipment at the Contractor's works.

At a later stage, during the site-erection, commissioning and trial operation periods of the equipment, the Employer's technical staff shall be trained by the Contractor in assembly, dismantling, commissioning and operations under supervision of the Contractor.

The number of trainees, training schedule and duration is defined in the Particular Technical Specification.


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11 ANNEXES The following Annexes form an integral part of the General Technical Specifications:

Annex A Equipment Designation System -Application Guide

Annex B Forms of Data Schedules

• Motor Data Schedule (MDS)

• Feeder Data Schedule (FDS)

• Cable Data Sheet (CDS)

• Cable Laying Schedule (CLS)

Annex C Painting System

Annex D Symbols and Abbreviations


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Section 1, General Technical Specifications Chapter 11 - ANNEXES

Annex A – Equipment Designation System (EDS)


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Introduction

General

This Application Guide is based on DIN Standard 40719 part 2 and has been prepared mainly for use in Hydropower Plant projects. The rules described herein are presumed mainly for designation of:

• Electrical and mechanical equipment items on diagrams, layouts and correspondingly (with suitable labels) on the installed equipment itself

• Various power plant areas and rooms

• Power and control cables

• Terminals and signals

• Spare parts

• Drawings and schedules (if required).

Particular Project Applications

The tables shall be currently completed with relevant details and kept up-to-date by one responsible person for the whole project (to avoid double-definitions or other confusions).

The completed/revised Guide versions shall be regularly distributed to all parties concerned and in the as-built form finally included in the Operation Manual.

Alpha-numeric Symbols

Various blocks/boxes have been used for description of the designation code forms. Within these boxes "A" stands throughout the whole document for identification letter and "N" for a number.


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Designation System Blocks

The equipment marking codes are composed as follows:

Block 1 Higher-level assignment showing correlation with other parts of the equipment with regard to location and/or function

A supplementary designation may be assigned to an item if it is desired to express its relation to a larger unit of a system, of which it is a part.

Block 2 Location of item

Block 3 Identification of item: A = kind of item B = number of item C = function of item

Block 4 Terminal and conductor markings

Qualifying symbols are used to distinguish the Blocks 1, 2, 3 and 4 of a complete designation. The different blocks with their qualifying symbols are shown below:

HIGHER BLOCK 1 = LEVEL

ASSIGNMENT

BLOCK 2 + LOCATION

3A 3B 3C

BLOCK 3 − KIND NUMBER FUNCTION

BLOCK 4 : TERMINAL

The qualifying symbol may be omitted if there is no ambiguity. There can be other symbols used in front of Block 4 to designate e.g. signals ("!"), etc.

The following sequence of designation blocks shall be used if "full identification" is required:


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Block: 1 2 3A 3B 3C 4

= HIGHER LEVEL ASSIGN-MENT

+ LOCATION

- KIND

NUMBER

FUNCTION

: TERMINAL

The identification Block 1 ("Plant") shall be entered in the title block of the schematic diagram and in the Blocks 3/4 shown at the items of equipment.


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Plant Identification Code (Block 1)

Sections of Block 1

The identification block is subdivided into the following 5 sections:

Section: 1 2 3 4 5

Qualifying Symbol = N AAA NN (A)A NN(N)

Position: G1 F1F2F3 FN A1A2 A3A4

Meaning: General Function Aggregate

The individual sections can be recognized by an alternating arrangement of numerals and letters.

The identification Block 1 has a maximum of 11 alphanumeric data positions.

The positions indicated in parenthesis can be omitted.

Complete sections only from right to the left hand side can be omitted from the codes.

The alphabetical data positions are often allotted a specific meaning, which is laid down in tables.

The numerical data positions are used for numbering of panels, items, cables, etc.

Example

Section: 1 2 3 4 5

Code: = 2 BFA 10 G 12

12th

outgoing el. feeder (drawer outfit)

from bus section (or panel) No. "10" of

switchgear FA

for 2nd generating unit


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Location Identification Code (Block 2)

The form of identification block for "location" of electrical equipment placed in switchboards is as follows:

Section: 1 2 3 4 5

Qualifying Symbol +

N AAA NN • (A)A NN

"•" only in Block 2 between sections 3 & 4 (to distinguish between Block 1 & 2 form)

The sections 1 and 2 are identical with Block 1.

The panels of one switchboard shall be numbered in section 3 (e.g. for bus 00 with 01, 02, 03, etc. for bus-section 10 with 11, 12, 13, etc.).

The vertical (columns) and the horizontal (row) spot identification can be described after separator "•" in section 4 and 5 (if required).

For location identification of other electrical equipment (machines, assemblies, etc.) the "room code" according to Section 10 here below can be used (if such identification is required).

Equipment Identification Code (Block 3)

The "Equipment" identification block is preceded by a minus sign (-); it consists of the parts 3A, 3B and 3C

Block: 3A 3B 3C

Section: 1 2 3

Qualifying Symbol - A N N (N) A (A, N)

Meaning: Kind Number Function

of electrical equipment item

For equipment identification, at least part 3B must be marked in the schematic diagram (if no confusion possible), whereas parts 3A and 3C may be added to part 3B as supplements.

The complete cable identification code comprise the target address (Block 1) and the cable designation (Block 3).


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Example

can be omitted

= 2 MEY 01 D 01 _ (J) 01 F

Low voltage Cable

Cable No. 1 Designation

Qualif. symbol

Motor No. 1 for

Governor oil pump Target Address

of Unit No. 2

Equipment Items Designation - Examples (Block 3)

Equipment Identification Codes consisting of a Kind Identifier and a Number

S 1 K 31 N 42

Qualifiying Symbol

Kind

Number

Equipment Identification Codes consisting of a Kind Identifier, a Number and a Function Identifier

S 1 A T 1 L1 T 1 L2

Qualifiying Symbol

Kind

Number

Function


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Complete Equipment Identification Code – Split Representation

Identification blocks (or parts thereof) which are the same for most of the items of equipment represented in a schematic diagram, e.g. the "Plant" identification block, are shown only once at a suitable place in the diagram, e.g. in the block. The complete code then comprises this common part and that which is marked next to the equipment symbol. Items not covered by the common part are marked (at or near their symbol) with the complete code (see in the following example: contactor contact =TB43 -K1 in diagram =AC11. Marking of the equipment location can proceed in a similar manner.

Example:

-S3 -K3 -K4

=TB43-K1 -K8 -K9

-K3 -K4 -K5

Block =AC 11

The complete identifying codes of all other symbols in the above example would read:

=AC11 -K3, AC11 -K4, =AC11 -K5, =AC11 -K8, AC11 -K9 and =AC11 -S3.

The equipment identification codes are found

inside enclosures, on or immediately adjacent to the particular item,

in the equipment or component list, complete with additional information,

in the parts list complete with additional information that is generally required for reordering.

Marking of Integrated Components

With integrated components, one item of equipment forms part of another, each having its own markings, e.g. modular assembly - A1 (superordinated item) and the transformer - T1 (superordinated item).


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Code of superordinated item

-A1

380V3~-T1

19V3~ 19V3~

-G1 -G2

~ ~

+24V +15V OV +15V +24V

Code of subordinated item

⊗ ⊗

Fig. 11.1: Integrated item of equipment forming part of plant =M3. The modular power pack -A1 consists of transformer -T1 and the power supplies -G1 and -G2. The complete identification codes read: =M3 -A1, =M3 -A1 -T1, =M3 -A1 -G1, =M3 -A1 -G2.

To designate an item of equipment which forms part of a superordinated item, the two identification blocks are joined together (that of the superordinated item being on the left).

Example: The complete identification code of a modular assembly consists of the "Plant" and "Kind, Number" blocks and reads =M3 -A1. The transformer built into this assembly is designated by the "Kind, Number" -T1 identification block (see Fig. 11.1).

The complete transformer identification code thus reads: =M3 -A1 -T1.

Additional Information

If required, the American standard designation of the protective relays and small apparatus can be used in "Block 3" of the equipment designation code.

Technical data and type designation can be indicated below the equipment identification code in smaller print.


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Terminal Identification Code (Block 4)

Section: 1 2 3

Qualifying Symbol : A NN(N) A(AN)

The "Terminal" block is used when

• the connections between items of equipment have been replaced by broken lines showing target or similar symbols, as illustrated in Fig. 11.2,

• terminals located in a plant other than the one to which the schematic diagram applies.

-11 -12 -131 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4

-17

-14 -15 -161 2 3 4 5 6 1 2 3 4 5 6 1 2 3

X1 1 2 3 4 5 6 7 8 9 10 11 12 13

11:1

-11:

2

-11:

4

-XI:3

-XI:2

-17:

1

-12:

2

-X1:

1

-12:

5

-16:

C

-14:

5

-XI:9

-XI:1

0

-X1:

1

-16:

C

-14:

6

-XI:1

1

-XI:5

-XI:6

-15:

5

-XI:8

-11:

3

-XI:7

-XI:4

13:1Terminal

Item of equipment

TerminalItem of equipment

TerminalItem of equipment

12:6

-XI:1

2

-XI:1

3

-11:

515

:4

11:6

-12:

4

-14:

1

-14:

3

-15:

1

-15:

3

-16:

B

-12:

3

12:5

-14:

2

-14:

4

-15:

2

-16:

A

Fig. 11.2: Typical "Terminal" Identification


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Cable Route Designation

For description of the route in which the cables shall be laid following (special) code combined from room identification and route section designation can be used:

Block: 1 3

Code: + AAANNANN(N) − A(N)NNA

Room Identification (see para. 10)

Route Section Designation

Example

+ UAA 02 R 15 − E (2) 15 B

Designation of room in which the particular tray section is installed (can be indicated only once in the floor/room layout drawing title block)

Voltage level (B - for HV/MV F - for LV ac/dc power K - for C&I <60 V Q - for communication)

15th Section

2nd Layer (from above)

Cable tray


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Room Designation

For the identification of various rooms in the power plant building (and switchyard) following code can be used:

Section: 1 2 3 4 5

Code: + (N) A AA N N A NN(N)

Room No. (per floor)

"R" for "room designation"

Floor (from deepest to highest)

Building/Yard designation

"U" for room designation code

Unit (not applicable here)

Example

+ U BA 02 R 15

Room number

Specific letter

2nd floor

Machine hall

Specific letter


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Designation of Equipment

Additional Examples of Description and Identification Key according to DIN 40 719

In the following list only a part of ME and SC is added. Some of the main divisions (e.g. F, and H) will not be applied for hydraulic power stations.

A Grid and distribution system

B Power transmission and aux. power supply

C Instrumentation and control equipment

D Instrumentation and control equipment

E Conventional fuel supply and residues disposal

F Handling of nuclear equipment

G Water supply and disposal

H Conventional heat generation

J Nuclear heat generation

K Reactor auxiliary system

L steam, water, gas cycles

M Main Machine Sets

ME Hydraulic Turbine Plant

MEA Turbine

From excl. turbine inlet or

from excl. isolating valve

to incl. turbine outlet or

to excl. isolating valve, incl. draft tube

MEB Isolating valve

MED Bearings

MEG Stabilizing air system

MEK Transmission gear

MEL Water depression air supply system

MES Shaft gland cooling system

MEV Lubricant supply system

N Process energy supply

P Cooling water supply

Q Auxiliary systems

R Gas generation and treatment

S Ancillary System

SC Stationary compressed air supply


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SCA Compressed air generation system

SCB Compressed air distribution system

SCC - SCU Stationary compressed air supplies

SCV Lubricant supply system

SCX Fluid supply system for control and protection equipment

SCY Control and protection equipment

T

U Structures

V

W Renewable energy plant

X Heavy machinery

Y

Z Workshop and office equipment


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Section 1, General Technical Specifications CHAPTER 11 - ANNEXES

Annex B - Forms of Data Schedules

Motor Data Schedule (MDS)

Feeder Data Schedule (FDS)

Cable Data Schedule (CDS)

Cable Laying Schedule (CLS)


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Description Unit Data Description Unit Data Description Unit Data CONSUMER / DRIVE / MACHINE INSTRUMENTATION Name of drive - Permissible starts per hour under EDS ident. No. - full load from Instrumentation diagram No. Manufacturer - - Cold condition Nos. Resistance temperature detectors Power demand of drive at coupling - Warm condition Nos. (RTDs), Pt 100 in stator winding - At nominal point kW Insulation class (IEC) - (HV motors): - At maximum capacity kW Design temperature rise of - 3x1 for temp. measurement yes/no RATED DATA stator winding K Temperature detectors (ther- Type designation - Thermal time constant mistors): Type of construction (IEC 34-7) - - Heating up min in stator winding (LV motors) Cooling method code (IEC 34-6) - - Cooling down min - 3 in series for alarm yes/no Degree of protection (IEC 34-5) - Perm. blocked-rotor time from - 3 in series for trip yes/no Duty type (IEC 34-1) - - Cold condition s Thermostat: in stator winding yes/no Frame or flange No. - - Warm condition s in bearing yes/no Rated output kW OTHER DATA Rated voltage Un V Moment of inertia J (m.r2) kg ⋅ m2 Remarks: Stator connection for Un Δ/Y Direction of rotation CW/CCW Rated frequency Hz (facing the shaft end) Rated speed 1/min Type of bearing at Overspeed test 1/min - Drive end (DE) - Rated current In A - Non-drive end (NDE) - Ratio of starting/rated current Type of lubrication - (ls/ln) at Un - Magnitude and direction Power factor at of axial thrust (if any) N - Rated output p.U. Number of terminal boxes for - 3/4 rated output p.U. - Power supply - EfficienCy at - Space heater - - Rated output % - Instrumentation - - 3/4 rated output % Degree of protection of terminal Rated torque Nm boxes (IEC) - Starting torque at Space heater Rev. Date/Signature Rev. Date/Signature - Un Nm - Rated power W - 0.85 Un Nm - Rated voltage V Project: Employer: Pull-out torque at Torque-speed diagram No. - Un Nm (motor plus load) Contractor: Manufacturer: - 0.85 Un Nm Motor outline drawing No. - 0.70 Un Nm Total mass of motor kg Date: Prepared by: Starting time (motor plus load) at Placed in room No. Starting torque at - Un s MOTOR DATA SCHEDULE (MDS) - 0.85 Un s


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Project: Employer:

Contractor: Prepared by: Date:

Feeder Data Schedule (FDS)

Position No. (in "List of Consumers") :

CONSUMER (EDS Identification No.): Type (Motor, Valve, Heating, etc.) :

Description/Name (Text) :

Data Schedule (MDS No. for consumers) :

Rated Voltage (V) :

Rated Power (kW) :

Rated Current (A) :

SWITCHBOARD (EDS Identification No.) : Feeder/Bay - EDS No. :

Feeder - Module type :

- Circuit diagram (No.) :

- Rated current (A) :

Switchgear - Type (fuse, CB, contactor) :

Protection - Type (SC/OL, EF) :

- Setting SC/OL (A) :

POWER CABLE (EDS Identification No.) : Cable - Type (CDS No.) :

- Cross section (mm2) :

- Diameter (mm) :

Material - Conductor :

- Insulation :


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Project: Employer:


Cable Data Sheet (CDS) Position No.:

CDS No. :

CABLE-Type (HV, LV / C & I) :

Cross Section (mm2) :

Manufacturer Name/Specification No. :

Manufacturer Identification/Catalogue No. :

Rated Voltage (V) :

Rated Current (A) *) :

Armoring :

Screening :

Sheath - Material :

- Color :

Overall Diameter (mm) :

Mass (kg/m) :

Min. Bending Radius (cm) :

Max. Pulling Force (kN) :

Max. Supply Length (m) :

CORE-No. and Type *) :

Material and Type (Cu/Al, solid/stranded) :

Insulation (material) :

Ohmic Resistivity (Ω/km at 20°C) :

Inductive Reactance (Ω/km) :

Operation Capacity (Microfarad/km) :

*) Legend: - "Rated Current": Cable single-laid in 30°C warm air, core temperature 50°C - Core type coding: P - Phase, E - Grounding, N - Neutral


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Project: Employer:


Cable Laying Schedule (CLS) Position No. :

CABLE (EDS-Identification No.) :

Target Equipment - 1st End (EDS No.) :

- 2nd End (EDS No.) :

Cable - Type (CDS No./Make) :

- Rated Voltage(V) :

- Cross Section (mm2) :

- Length (m) :

CORE CODING AND TERMINATION *)

Core Address at Target 1 Address at Target 2 Connection

No. Color (Identification No. of terminals) Diagram No.

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : CABLE ROUTING (Tray Section EDS-No.) **)

1 : 2 : 3 : 4 : 5 : 6 : 7 : 8 : 9 : 10 : 11 : 12 : 13 : 14 : 15 : 16 : 17 : 18 : 19 : 20 : Remarks: *) Cable core coding with color or with numbers printed on the insulation shall be used.

Cable cores when being connected shall be designated with corresponding terminal identification numbers (or phase color) on both ends.

**) The corresponding EDS designated cable route sections shall be indicated on the tray layouts.


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Section 1, General Technical Specifications

CHAPTER 11 - ANNEXES Annex C - Painting System

A Gates stoplog and trashracks incl. armatures, hydraulic hoist etc.

Internal surfaces of steel lining penstock, turbine distributes, valves and other ferrous surfaces.

B External surfaces of penstocks, gantries, cranes, lifting beams fixed hoist supports and other drive supports.

C External Surfaces of indoor ferrous parts such as valves, connection pipes, oil carrying tanks and pipes, supporting structures, gantries etc.

D Control cabinet panels, cubicles, electric meters.

E Interior surfaces of oil tanks.

F Frames, cover plates, pipes and tubes and miscellaneous steel parts not especially mentioned.


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PAINTING SYSTEM Type Description Surface

Preparation Paint System Main Dry Film

Thickness in μm Remarks

A.

- Gates, stoplogs and

trashracks incl. armatures, hydraulic hoists, etc.

Sa 2 1/2 - 3

Prime Coat: 1 x zinc dust primer, 2-component Base : epoxy resin

2 x 40

The pure metallic zinc shall be at least 92% of the polymerized film

- Internal surfaces of steel

linings, penstock, turbine distributor, valves and other wetted internal ferrous surfaces

Intermediate Coat : 2 x micaceous iron oxide paint, 2-component Base: epoxy resin

2 x 100

This paint system is for temperatures up to 120°C

Finish Coat : 1 x topcoat, 2-component Base : epoxy resin

1 x 100 __________

The colors of intermediate and finish coats shall be black - brown - black

Total

380 ========

PAINTING SYSTEM


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Type Description Surface



B. - External surfaces of

penstocks, Gantries, Cranes, Lifting Beams, Fixed Hoist supports and other Drive Supports

Sa 2 1/2 - 3

Prime Coat : 1 x zinc dust primer, 2-component Base : epoxy resin

1 x 50 The pure metallic zinc shall be at least 92% of the polymerized film

Intermediate Coat : 2 x micaceous iron oxide paint, 2-component Base : epoxy resin

2 x 80 This paint system is for temperatures up to 60°C

Finish Coat : 1 x micaceous iron oxide paint, colored, 2-component Base : epoxy resin

1 x 80

__________

Total

290 =========


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C.

- External surfaces of indoor ferrous

parts such as valves, connection pipes, oil carrying tanks and pipes, supporting structures, gantries, etc.

Sa 2 1/2 - 3

Prime coat : 1 x zinc dust primer, 2-component Base :epoxy resin

1 x 50

The pure metallic zinc shall be at least

92% of the polymerised film

Intermediate Coat : 2 x micaceous iron oxide paint, 2-component Base : epoxy resin

2 x 80

This paint system is for temperatures up to 120°C

Finish Coat : 1 x topcoat, 2-component Base : epoxy resin

1 x 50 __________

Total

260 =========


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D. - Control cabinets, panels,

cubicles, electric motors

Sa 3 and de-grease before painting

Prime Coat: 2 x zinc chromate primer, 2-component Base : epoxy resin

2 x 40

Finish Coat : 2 x topcoat, 2-component Base : epoxy resin Total

2 x 50

__________

180 =========


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E.

- Interior surfaces of oil tanks

Sa 2 1/2 - 3

2 x thixotrop consistent paint Base : epoxy resin

2 x 220

__________

Total

440

=========


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PAINTING SYSTEM Type escription Surface



F. Frames, cover plates, pipes

and tubes, and miscellaneous steel parts not especially mentioned

Hot-dip-galvanized as specified in Section 2.10.6.3 and de-grease before painting

Intermediate Coat : 1 x micaceous iron oxide paint, 2-components Base : epoxy resin

1 x 80 All the parts inaccessible for painting shall be only hot-dip galvanized

Finish Coat : 1 x topcoat, 2-component Base: epoxy resin

1 x 50

__________

Total, incl. zinc

200 =========


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Section 1, General Technical Specifications

CHAPTER 11 - ANNEXES Annex D - Symbols and Abbreviations


Project 300854.01 Page 147/150

Length, Area and Volume

cm centimeter

cm2 square centimeter

ha hectare

km kilometer

km2 square kilometer

l liter

m meter

m2 square meter

m3 cubic meter

mm millimeter

mm2 square millimeter

rad radian

µm micron = 10-6 m

Time and Time Derived Units

d day

h hour

Hz hertz (periods per second)

km/h kilometers per hour

min minute

mm/s millimeters per second

m/s meters per second

m/s2 meters per second squared (acceleration)

m3/s cubic meters per second

s second


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Mass, Force and Derived Units

atm standard atmosphere = 101325 Pa

bar bar = 105 N/m2

daN deca Newton = 10 N g gram = 10-3 kg

J Joule = 1 Nm (Newton-meter)

kg kilogram

kJ kilojoule = 103 J

kg/m3 kilograms per cubic meter

mg milligram = 10-6 kg

mg/l milligrams per liter

MPa Megapascal = 106 Pa

N Newton

N/m2 Newton per square meter

N/mm2 Newton per square millimeter

Pa Pascal = 1N/m2

t ton = 103 kg

t/m3 ton per cubic meter

Electrical Units

A ampere

kVA kilovolt ampere

kW kilowatt = 103 W

kWh kilowatt hour

MW megawatt = 106 W

V volt

W watt = 1 J/s


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Electrical Engineering Abbreviations

AC Alternating Current

CB Circuit Breaker

CDS Cable Data Sheet

CLS Cable Laying Schedule

CT Current Transformer

DC Direct Current

FDS Feeder Data Schedule

GB Gigabyte

HRC High Rupturing Capacity

HV High Voltage (cables)

I&C Instrumentation and Control

LV Low Voltage

MB Megabyte

MCB Miniature Circuit Breaker

MCC Motor Control Center

MDS Motor Data Schedule

MV Medium Voltage

NC Normally Closed

NO Normally Open

PE Protective Grounding

PEN Protective Grounding Neutral

rms Root Mean Square

SCADA Supervisory, Control and Data Acquisition

SPDT Snap Action Contact Device

TN Neutral Wire Connection

UPS Uninterruptible Power Supply

VT Voltage Transformer


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Other Symbols and Abbreviations

approx. approximately

asl above sea level

bhp brake horse power

C.I. Cast Iron

CIF cost, insurance and freight

dia. or diam. diameter

EDS Equipment Designation Schedule

fig. figure

FOB free on board

hp horsepower

horiz. horizontal

HT high tensile (steel)

H.W.L high water level

max. maximum

M.F.L maximum flood level

min. minimum

M.O.L. minimum operating level

no. number (units), as in 6 no.

No. number (order), as in No. 6

temp. temperature

vert. vertical

vol. volume

wt weight

°C degrees Celsius

% percent

General Technical Spacifications for Keban HEPP Rehabilitation Works

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