Professional Documents
Culture Documents
KEBAN HPP
Rehabilitation Works
Keban Rehabilitation
Structure of Tender Documents
Volume 3 Contract
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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General Technical Specification ii
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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General Technical Specification v
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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General Technical Specification vi
11 ANNEXES 119
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.
1.3 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.
- BS British Standards
Surfaces
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.
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.
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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One copy of the submitted drawings will be returned to the Contractor with one of the
following stamps:
"Approved", or
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.
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.
2.2 Drawings
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.
(buildings, rooms, foundations, ducts, etc.) and reserved areas (for pipes, cables, lines,
etc.) in relation to each other and to agreed coordinates and boundaries.
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.
The drawings shall - where applicable - substantially conform to the Tender Drawings
and shall show:
• 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.
• 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.
2.3 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.
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.
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.
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.
For standard proprietary equipment (for example valves, switchgear, control gear,
relays, transmitters, indicators, lighting fittings, etc.) catalogues or pamphlets can be
submitted.
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).
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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• 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.
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.
2.6 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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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
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.
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.
The entire testing and adjustment procedure required for the Works after overhauls
and during operation shall be described.
e) Maintenance Instructions
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.
• 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.
f) As-built drawings.
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 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.
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.
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
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.
• 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.
• 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.
• 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 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.
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.
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.
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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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 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.
4.2.1 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 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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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.
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.
Stresses resulting from these loads shall not exceed permissible stresses.
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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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.
4.6.1 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.
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.
Cubicles and similar units shall also bear this identification number on the rear side if
rear access is possible.
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.
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).
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.
4.7.1 Painting
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.
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
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.
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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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.
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:
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.
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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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).
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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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.
• 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.
(1) Material
For galvanizing, only original blast-furnace raw zinc shall be applied, which shall have
a purity of 98.5%.
(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.
Bolts, nuts, washers, locknuts and similar hardware shall be galvanized in accordance
with the relevant standards. Excess speller shall be removed by centrifugal spinning.
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.
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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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.
4.8.1 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 %.
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.
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
Small risk 0 0 1
Stairs, Rails, doors
Medium risk 2 2 5
Cranes, roof trusses,
bridges
High risk 3, 4, 5, 6 3, 4, 5, 6 3, 4, 5, 6
Penstocks, steel linings,
spiral casing, guide vane,
runner, draft tube, gates,
stoplogs etc.
Any structure not especially mentioned shall be classified by the Contractor and shall be
subject to approval by the Employer.
Signification
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.
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.
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.
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.
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.
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.
All radiographic films and data shall become the property 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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5.1 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.
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.
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.
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.
5.7.1 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.
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.
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.
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.
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.
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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Pressures gauges shall be provided with a damping liquid, e.g., glycerin, to compensate
vibrations.
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.
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.
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:
Servomotor- Danger Limit Danger Limit Danger Limit Danger Limit Condition
control Oil Threshold Condition Threshold Condition Threshold Condition Threshold
Initial Index Initial Index Initial Index 0.1 0.2 +/-15% of ref. +/-20% of By particle counting
value ref. value
+0.7 +0.9 +0.7 +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
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.
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.
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.
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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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.
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.
Manufacturing ISO 8306: 1985, Overhead traveling and portal bridge cranes,
and installation Tolerances for cranes and tracks
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.
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.
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.
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.
The permissible design stresses for materials, bolts, rivets, etc. are given in DIN 18800.
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.
The materials used for general steel structures shall conform to mild steel FE 360 B and
FE 510 C or ASTM A 36.
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.
The factor of safety for wire ropes of gate hoists should not be less than 8, as calculated
by using the following equation:
F
≥8
L
N
W⋅v
Output =
6.12 ⋅ η
[kW ]
1 Drum 0.95
* Friction coefficient
Drums to have 2 spare turns on the anchor end and one spare turn on the other end.
Hydraulic cylinder rods are to be sized to withstand earthquake vibration in the fully
extended position without permanent distortion or damage.
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.
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.
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.
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.
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.
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 %.
5.17.2.1 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.
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.
5.17.3.1 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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No structural welding shall commence until members to be joined have been properly
aligned and braced to prevent distortion.
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.
5.17.4.1 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.
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.
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.
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.
In the case of repairing a crack, the cause of cracking shall first be established
satisfactorily before repair is allowed.
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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.
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.
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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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.
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:
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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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.
Frequency 50Hz + 4% / - 6%
Frequency 50Hz + 4% / - 6%
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.
6.4.3 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:
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.
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.
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.
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.
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.
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.
For the transport of motors equipped with ball or roller bearings, special bearing inserts
shall be provided to prevent transport damage.
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.
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.
6.4.12 Vibrations
In order to prevent undue and harmful vibrations, all motors shall be statically and
dynamically balanced.
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
Site Tests:
• Measurement of insulation resistance
• Measurement of electrical values such as (starting) current, voltage
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Doors 2,0 mm
Backplane 1,5 mm
Roof 1,5 mm
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.
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 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.
All panels/cubicles shall have approx. 10% spare room for mounting of future auxiliary
devices.
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.
Phase rotation and color markings shall be employed throughout the Works.
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.
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.
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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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.
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.
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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• 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.
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.
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) “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.
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.
• 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.
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.
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
- switched plus arbitrary
48 VDC-Network:
- Positive + 48 V + white
- Negative - 48 V - black
Voltage Transformer
Circuits:
- Phase R, S, T, L1, L2, L3 black Imprinted numbers
Protective grounded
Protective grounded neutral
- Grounded N black Imprinted numbers
neutral
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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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.
The secondary windings shall be wired to suitable terminal boards and grounded at one
point in the circuit.
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.
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.
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.
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.
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.
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.
All cables shall be at least flame retardant according to IEC Publication 60332.
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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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:
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.
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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Multicore cables with more than 7 cores shall have approx. 20% spare cores for future
use.
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.
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.
Accessible cable galleries shall have fire-barriers at suitable spacing including normally
open fire doors, which are closed automatically in case of fire.
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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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
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.
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.
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.
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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7.1.1 General
The following operation levels shall be implemented:
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.
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.
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.
Each device shall be operable from one of the man-machine interfaces. The interlocking
shall be programmed in the programmable controller.
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.
7.2.1 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.
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.
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.
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.
The indicating instruments and recorders shall have the following or similar sizes:
The control switches, adjusters, etc., on the panels and desks shall harmonize with the
utilized indicator sizes.
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.
• 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.
7.4.1 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.
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.
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.
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.
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).
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 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.
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 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.
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.
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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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.
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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8.1 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.
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.
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
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.
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.
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.
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.
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.
• 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.
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.
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.
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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9.1 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.
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.
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.
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:
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.
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.
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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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.
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:
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:
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).
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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HIGHER
BLOCK 1 = LEVEL
ASSIGNMENT
BLOCK 2 + LOCATION
3A 3B 3C
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.
Block: 1 2 3A 3B 3C 4
HIGHER
= LEVEL + LOCATIO - KIND NUMBER FUNCTIO : TERMINA
ASSIGN- N N L
MENT
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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Sections of Block 1
Section: 1 2 3 4 5
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
2 BFA 10 G 12
Code: =
12th
switchgear FA
Section: 1 2 3 4 5
+
"•" only in Block 2 between sections 3 & 4
(to distinguish between Block 1 & 2 form)
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).
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
A N N (N) A (A, N)
Qualifying Symbol -
Meaning: Kind Number Function
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
S 1 K 31 N 42
Qualifiying Symbol
Kind
Number
S 1 A T 1 L1 T 1 L2
Qualifiying Symbol
Kind
Number
Function
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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:
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.
in the parts list complete with additional information that is generally required for
reordering.
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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-A1
380V3~
-T1
19V3~ 19V3~
-G1 -G2
~ ~
⊗ ⊗
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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Section: 1 2 3
Terminal
-17:1
-12:2
-14:5
11:1
-11:2
12:6
-16:C
-12:5
-X1:1
-XI:2
-XI:3
-XI:4
13:1
-11:4
Item of equipment
-17
Terminal
-XI:10
-XI:12
-XI:13
-XI:11
-16:C
-XI:5
-XI:6
-XI:9
-XI:7
-X1:1
-11:3
-15:5
-14:6
15:4
-XI:8
-11:5
Item of equipment -16:A
-16:B
-12:3
-12:4
-14:1
-14:3
-15:1
-15:2
-15:3
Terminal
12:5
-14:2
11:6
-14:4
Item of equipment
X1 1 2 3 4 5 6 7 8 9 10 11 12 13
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
Example
+ UAA 02 R 15
− E (2) 15 B
Designation
of room in which the Voltage level
particular tray section is (B - for HV/MV
installed (can be indicated F - for LV ac/dc power
only once in the floor/room K - for C&I <60 V
layout drawing title block) Q - for communication)
15th Section
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
Building/Yard designation
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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Project: Employer:
Project: Employer:
Project: Employer:
: : : : :
: : : : :
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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C External Surfaces of indoor ferrous parts such as valves, connection pipes, oil carrying tanks
and pipes, supporting structures, gantries etc.
F Frames, cover plates, pipes and tubes and miscellaneous steel parts not especially mentioned.
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PAINTING SYSTEM
A. - Gates, stoplogs and Sa 2 1/2 - 3 Prime Coat: The pure metallic zinc shall be at
trashracks incl. 1 x zinc dust primer, 2-component 2 x 40 least 92% of the polymerized film
armatures, hydraulic Base : epoxy resin
hoists, etc.
__________
Total 380
========
PAINTING SYSTEM
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B. - External surfaces of Sa 2 1/2 - 3 Prime Coat : The pure metallic zinc shall be at
penstocks, Gantries, Cranes, 1 x zinc dust primer, 2-component 1 x 50 least 92% of the polymerized film
Lifting Beams, Fixed Hoist Base : epoxy resin
supports and other Drive
Supports
Finish Coat :
1 x micaceous iron oxide paint, 1 x 80
colored, 2-component
Base : epoxy resin
__________
Total 290
=========
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PAINTING SYSTEM
C. - External surfaces of indoor ferrous Sa 2 1/2 - 3 Prime coat : The pure metallic zinc shall be at least
parts such as valves, connection pipes, 1 x zinc dust primer, 2-component 1 x 50
oil carrying tanks and pipes, Base :epoxy resin 92% of the polymerised film
supporting structures, gantries, etc.
Finish Coat :
1 x topcoat, 2-component 1 x 50
Base : epoxy resin
__________
Total 260
=========
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PAINTING SYSTEM
Finish Coat :
2 x topcoat, 2-component 2 x 50
Base : epoxy resin
__________
Total
180
=========
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PAINTING SYSTEM
Total 440
=========
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PAINTING SYSTEM
F. Frames, cover plates, pipes Hot-dip-galvanized Intermediate Coat : All the parts inaccessible for
and tubes, and miscellaneous as specified in 1 x micaceous iron oxide paint, 1 x 80 painting shall be only hot-dip
steel parts not especially Section 2.10.6.3 2-components galvanized
mentioned and de-grease Base : epoxy resin
before painting
Finish Coat :
1 x topcoat, 2-component 1 x 50
Base: epoxy resin
__________
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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