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EÜAŞ

KEBAN HPP

Rehabilitation Works

EÜA Ş KEBAN HPP Rehabilitation Works April 28, 2008 Rev 001 General Technical Specification (GTS) KEBAN

April 28, 2008 Rev 001

Ş KEBAN HPP Rehabilitation Works April 28, 2008 Rev 001 General Technical Specification (GTS) KEBAN REHABILITATI

General Technical Specification (GTS)

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 milos.mancal@ewe.ch

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 david.fauriel@edf.fr

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 dolsar@dolsar.com.tr

Keban HPP General Technical Specification

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 milos.mancal@ewe.ch

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 david.fauriel@edf.fr

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 dolsar@dolsar.com.tr

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)

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 milos.mancal@ewe.ch

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 david.fauriel@edf.fr

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 dolsar@dolsar.com.tr

Keban HPP General Technical Specification

 

Project 300854.01

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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

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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

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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

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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

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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

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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

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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

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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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General Technical Specification

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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

- AISI

- ANSI

- ASME

- ASTM

- AWS

- BS

- CCITT

- CECT

- CMAA

- DIN

- IEC

- IEEE

- IIW

- ICEA

- ISO

- JEC

- JIS

- NEMA

American Gear Manufacturer Association

American Iron and Steel Institute

American National Standards Institute

American Society of Mechanical Engineers

American Society for Testing and Materials

American Welding Society

British Standards

International Telephone & Telegraph Consulting committee

European committee for Manufacturing of Boilers & Kindred Steel Structures

Crane Manufacturers Association of America

Deutsches Institut für Normung

International Electrotechnical Commission

Institute of Electrical and Electronic Employers

International Institute of Welding

Insulated Power Cable Employer's Association

International Standards Organization

Standards of the Japanese Electrotechnical Committee

Japan Industrial Standards

National Electrical Manufacturers Association

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General Technical Specification

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- NFPA

- VDE

- VDI

- SIS

National Fire Protection Association

Verein Deutscher Elektroingenieure

Verein Deutscher Ingenieure

Swedish Standards Institute

1.3.3 Basic Design, Manufacturing and Testing Standards

ISO System for Limits and Fits, Part I, General

ISO/R286-1963

Tolerances and Deviations

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

ASTM-E23

Materials

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:

Works identification number

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

terminal

point

connection

at

each

end

with

cubicle/Works

identification

and

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:

denomination and description of signals

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:

denomination and description of signals

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:

Works identification number

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:

Colored sheets:

70 g/m² to 106 g/m 2 ;

not less than 70 g/m 2 .

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