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EÜAŞ

KEBAN HPP
Rehabilitation Works

April 28, 2008


Rev 001

General Technical Specification


(GTS)

KEBAN REHABILITATION CONSULTANT

ELECTROWATT-EKONO AG ELECTRICITE DE FRANCE DOLSAR ENGINEERING LIMITED


Hardturmstrasse 161, P.O. Box David Fauriel Kennedy Caddesi 43, Kavaklidere
CH-8037 Zurich / Switzerland FR-73373 Le Bourget-du-Lac / France TR-6660 Ankara / Turkey
Tel. +41 76 356 22 79 Tel. +33 4 79 60 60 73 Tel. +90 312 417 90 00
Fax +41 44 355 55 64 Fax +33 4 79 60 62 40 Fax +90 312 418 10 66
E-mail milos.mancal@ewe.ch E-mail david.fauriel@edf.fr E-mail dolsar@dolsar.com.tr
Keban HPP
General Technical Specification

KEBAN REHABILITATION CONSULTANT

ELECTROWATT-EKONO AG ELECTRICITE DE FRANCE DOLSAR ENGINEERING LIMITED


Hardturmstrasse 161, P.O. Box David Fauriel Kennedy Caddesi 43, Kavaklidere
CH-8037 Zurich / Switzerland FR-73373 Le Bourget-du-Lac / France TR-6660 Ankara / Turkey
Tel. +41 76 356 22 79 Tel. +33 4 79 60 60 73 Tel. +90 312 417 90 00
Fax +41 44 355 55 64 Fax +33 4 79 60 62 40 Fax +90 312 418 10 66
E-mail milos.mancal@ewe.ch E-mail david.fauriel@edf.fr E-mail dolsar@dolsar.com.tr
Keban HPP
General Technical Specification

Keban Rehabilitation
Structure of Tender Documents

Volume 0 Invitation and Instructions to Bidders

Volume 1 Administration Specifications

Volume 2 Technical Specifications

− Section 1 General Technical Specifications (GTS)

− Section 2 Common Particular Technical Specifications with time schedule


(CPTS)

− Section 3 Particular Technical Specifications ( PTS);


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

− Section 4 Data Sheets (DS);


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

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

− Section 6 Work Programme

Volume 3 Contract

Volume 4 Standard Forms

− Section 1 Price Schedule (PS);


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

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


(From Appendix 1 to Appendix 27)

KEBAN REHABILITATION CONSULTANT

ELECTROWATT-EKONO AG ELECTRICITE DE FRANCE DOLSAR ENGINEERING LIMITED


Hardturmstrasse 161, P.O. Box David Fauriel Kennedy Caddesi 43, Kavaklidere
CH-8037 Zurich / Switzerland FR-73373 Le Bourget-du-Lac / France TR-6660 Ankara / Turkey
Tel. +41 76 356 22 79 Tel. +33 4 79 60 60 73 Tel. +90 312 417 90 00
Fax +41 44 355 55 64 Fax +33 4 79 60 62 40 Fax +90 312 418 10 66
E-mail milos.mancal@ewe.ch E-mail david.fauriel@edf.fr E-mail dolsar@dolsar.com.tr
Keban HPP Project 300854.01
General Technical Specification i

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

2.5.13 List of EDS Identification Numbers 17


2.6 Calculations 17
2.7 Installation and Commissioning Procedures 18
2.7.1 Installation Procedures 18
2.7.2 Pre-Commissioning Procedures 18
2.7.3 Commissioning Procedures 18
2.8 Operation and Maintenance Manuals 18
2.8.1 Contents 18
2.8.2 Format and Compilation 20
2.8.3 Revisions and Supplements 20
2.9 Progress Reports during Design and Manufacturing 21
2.10 Test Reports During Manufacturing 22
2.11 Progress Reports During Installation at Site 22
2.12 Test report during installation on site 23
2.13 Commissioning Report 23

3 SPARE PARTS AND TOOLS 24


3.1 Spare Parts 24
3.1.1 Specified Spare Parts 24
3.1.2 Recommended Spare Parts 24
3.2 Tools and Appliances 24

4 DESIGN AND MANUFACTURE 26


4.1 Design and Construction Requirements 26
4.2 Allowable Stress 27
4.2.1 General 27
4.2.2 Custom designed equipment such as turbine, generator, main inlet valve etc. 27
4.2.3 Standard equipment 28
4.2.4 Hoisting equipment and steel structures 28
4.3 Design Criteria 28
4.3.1 Seismic Loads 29
4.3.2 Wind Load 29
4.4 Standardization of Works 29
4.5 Noise 30
4.6 Identification Plates and Labels 30
4.6.1 General 30
4.6.2 Manufacturer's Nameplates 30
4.6.3 Identification Plates 31
4.6.4 Instruction Plates 31
4.6.5 Warning Plates 31
4.6.6 Labels for Conduits, etc. 31
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General Technical Specification iii

4.6.7 Labels for Cables 31


4.6.8 Rating Plates 31
4.6.9 Single-Line Diagrams 31
4.6.10 Key System for Electric Boards 32
4.7 Corrosion Protection 32
4.7.1 Painting 32
4.7.1.1 Scope of Work 32
4.7.1.2 Painting Materials 32
4.7.1.3 Workmanship 33
4.7.1.4 Painting Systems 36
4.7.1.5 Color Code 37
4.7.1.6 Repair of Primer and Finish Coats 37
4.7.2 Galvanizing 38
4.7.3 Finished Surfaces 39
4.7.4 Unfinished Surfaces 39
4.7.5 Protection of Machined Surfaces 39
4.7.6 Rounding, Chamfers, Edges 39
4.8 Welding and Heat Treatment 39
4.8.1 General 39
4.8.2 Welding 40
4.8.3 Welding Qualifications 42
4.8.4 Welding Work 42
4.8.5 Heat Treatment 44
4.8.6 Quality and Procedure Control 44
4.8.7 Defects and Repairs 45

5 MECHANICAL WORKS, METAL AND STEEL STRUCTURES 46


5.1 General 46
5.2 Bolts, Screws, Nuts, etc. 46
5.3 Seals 47
5.4 Protection Guards 47
5.5 Drives and Gears 47
5.6 Lubrication, Lubricants, Fuel 47
5.7 Piping, Fittings, Valves and Gates 48
5.7.1 General 48
5.7.2 Water Piping and Fittings 49
5.7.3 Valves, Gates 49
5.7.4 Oil Piping 50
5.7.5 Pipe Supports and Hangers 50
5.8 Mechanical Instruments 51
5.9 Pressure Oil Systems 51
5.9.1 Hydraulic Pressure Units 51
5.9.2 Manufacturing and Tests 51
5.9.3 Maintenance 52
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General Technical Specification iv

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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6.6 Instrument Transformers 86


6.7 Protection Devices 86
6.8 Auxiliary Equipment 87
6.8.1 Auxiliary Switches 87
6.8.2 Control Switches 87
6.8.3 Anti-Condensation Heaters 88
6.8.4 Electrical Connections 88
6.9 Cables and Cable Laying 88
6.9.1 General 88
6.9.2 Standards 89
6.9.3 Insulation Materials 89
6.9.4 Rated Voltages and Test Voltages 89
6.9.5 Voltage Drops 90
6.9.6 Power Cables 90
6.9.7 Instrumentation, Control and Communication Cables 90
6.9.8 Cable Laying 91
6.9.8.1 General 91
6.9.8.2 Partition and Sealing 93
6.9.8.3 Cable Arrangement 93
6.9.9 Cable Termination 94
6.9.10 Tests 94
6.9.10.1 Workshop tests 94
6.9.10.2 Site tests 94
6.10 Equipment Grounding 95
6.11 Explosion-Proof Works 95
6.11.1 General 95
6.11.2 Definition of Hazardous Locations 95
6.11.3 Design Features 96

7 INSTRUMENTATION AND CONTROL EQUIPMENT (I&C) 97


7.1 Operation Levels 97
7.1.1 General 97
7.1.2 Operation Level 0 97
7.1.3 Operation Level 1 98
7.1.4 Operation Level 2 98
7.1.5 Operation Level 3 98
7.2 Operation Modes 99
7.2.1 General 99
7.2.2 Manual 99
7.2.3 Step by Step 99
7.2.4 Automatic 99
7.3 Design Criteria 100
7.3.1 General 100
7.3.2 Sizes of Indicators, Recorders, etc. 100
7.3.3 Transmitter Racks and Piping 101
7.3.4 Special Local Conditions 101
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General Technical Specification vii

7.4 Measuring Systems 101


7.4.1 General 101
7.4.2 Flow Measurements 102
7.4.3 Temperature Measurements 102
7.4.4 Pressure Measurements 102
7.4.5 Level Measurements 103
7.4.6 Electrical Measurements 103
7.4.7 Position Measurements 104
7.4.8 Limit Switches 105
7.4.9 Contact Devices 105
7.4.10 Vibration measurement 105
7.5 Interlocking and Lockout System 105
7.6 Tests 105

8 TRANSPORT AND INSTALLATION 106


8.1 General 106
8.2 Packing 106
8.3 Marking 107
8.4 Transport and Storage 107
8.5 Preparation and Installation 108
8.6 Reference Points 108
8.7 Installation Works 109
8.8 Civil Site Work 110
8.9 Safety Precautions 111
8.10 Fire Protection and Fire Fighting 111
8.11 Cleaning Up 112

9 INSPECTIONS AND TESTS 113


9.1 General 113
9.2 Test Certificates 113
9.3 Testing 114
9.4 Tests at Manufacturer's Works 115
9.4.1 General 115
9.4.2 Type Tests 116
9.4.3 Routine Tests 116
9.5 Tests on Completion 116
9.6 Reliability Run 117

10 STAFF TRAINING 118


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General Technical Specification viii

11 ANNEXES 119

Annex A Equipment Designation System -Application Guide


Annex B Forms of Data Schedules
Annex C Painting System
Annex D Symbols and Abbreviations
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1 GENERAL REQUIREMENTS

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

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

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

1.2 Scope of Work


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

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

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

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

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

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

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

The Contractor shall keep on Site during the period of the site works the applicable
Standards and Codes of Practice concerning the site works in general, and the field tests
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of materials and equipment in particular. One set of these documents shall be provided
by the Contractor to the Employer. The list of these documents established by the
Contractor shall be submitted to the Employer prior starting the site works.

1.3.1 Certification of Contractor


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

1.3.2 Standards for General Application


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

- AGMA American Gear Manufacturer Association

- AISI American Iron and Steel Institute

- ANSI American National Standards Institute

- ASME American Society of Mechanical Engineers

- ASTM American Society for Testing and Materials

- AWS American Welding Society

- BS British Standards

- CCITT International Telephone & Telegraph Consulting committee

- CECT European committee for Manufacturing of Boilers &


Kindred Steel Structures

- CMAA Crane Manufacturers Association of America

- DIN Deutsches Institut für Normung

- IEC International Electrotechnical Commission

- IEEE Institute of Electrical and Electronic Employers

- IIW International Institute of Welding

- ICEA Insulated Power Cable Employer's Association

- ISO International Standards Organization

- JEC Standards of the Japanese Electrotechnical Committee

- JIS Japan Industrial Standards

- NEMA National Electrical Manufacturers Association


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- NFPA National Fire Protection Association

- VDE Verein Deutscher Elektroingenieure

- VDI Verein Deutscher Ingenieure

- SIS Swedish Standards Institute

1.3.3 Basic Design, Manufacturing and Testing Standards

ISO System for Limits and Fits, Part I, General ISO/R286-1963


Tolerances and Deviations ISO/R1829-1975

Permissible Machining Variations in ISO/2786-1973


Dimensions Without Tolerance Indication

Screw Threads ISO 68-1973


ISO 262-1973 ISO/R724-
1978

General Principles for the Verification of the ISO 2394-1973


Safety of Structures

Methods and Definitions for Mechanical Testing ASTM-A370


of Steel Products

Tension Testing of Metallic Materials ISO/R82-1959

Notched Bar Impact Testing of Metallic ASTM-E23


Materials ISO/R83-1976

Bend Test for Steel ISO/R85-1959

Liquid Penetrant Inspection ASTM-E165

Recommended Practice for Radiographic ASTM- E94


Testing

Ultrasonic Examination of Heavy Steel Forgings ASTM-A388

Guided Bend Test for Ductility of Welds ASTM-E190

Welders' Qualification Tests AWS (American Welding


Society) Group B,
DIN EN 287

Preparation of Steel Surfaces for Painting by SIS 05-5900


Sandblasting

Designation of Degree of Rusting of Painted DIN 5321


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Surfaces

Certificates of Material Testing DIN 50049

1.3.4 Material Standards


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

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

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

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

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

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

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

1.4 Units of Measurements


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

1.5 Works Identification System


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

The Contractor’s Works Identification System shall be submitted for the Employer's
approval prior to implementation. The Employer may select one joint Identification
System for the entire Project (including works beyond this contract) and reserves the
right to deviate from the Contractors proposal.
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The system shall be based upon area codes allocated to each main area (e.g. control
room, relay room, switchyard, turbine room), an equipment code composing an
equipment identifier and a unique sequence number.

Extracts of an application guide of proposed Equipment Designation System (EDS)


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

1.6 Construction Program


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

The "Construction Program" shall be submitted in accordance with the Commercial


conditions of contract, and shall include the following information for individual parts
or equipment:
− Design work
− Model Testing
− Shop work
− Shop Testing
− Transport to the Site
− Preparations at the Site
− Erection and commissioning
− Acceptance testing
− Trial operation
− Handing over
− Removal of erection equipment and clearing of the Site
− Interdependence with work of other Contractors.

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

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

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

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

Technical documents provided by the Contractor shall be folded down to DIN Standard
size A4 in size. Prints shall be on durable paper, with dark lines on a white background.
The Technical documents shall show the following particulars either on the title page
for A4 size or in the lower right hand corner for A1 or A3 size:
• Name of Employer
• Name of Consultant
• Name of Contractor
• Project title
• Contract number and title
• Title of technical documents (location, item and detail)
• Scale
• Date of technical documents
• Technical document number
• Revision identification
• Serial number in accordance with drawing classification system
• Signature of the Contractor’s Representative.

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

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

Unless specified differently elsewhere a period of twenty eight (28) days after the
receipt of design and drawings shall be allowed for approval or comments. Another one
(1) week shall be allowed for return mail.
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Claims or extensions of time will not be granted on account of late submission of


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

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

"Approved", or

"Approved Except as Noted" (authorizing the Contractor to proceed with the


Contractual works taking account of the Notes) or

"Returned for Correction and Resubmission".

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

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

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

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

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

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

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

The preparation of drawings, computations or other technical documents shall not be


sublet by the Contractor without the written authorization of the Employer. In such a
case the Contractor shall be fully responsible for such drawings, computations and other
technical documents as if he were the author.
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On drawings, catalogue sheets or pamphlets of standard Works submitted to the


Employer the applicable types, paragraphs, data, etc., shall either be marked
distinctively or the non-applicable parts shall be crossed out. Documents not marked in
such a manner will not be accepted and approved by the Employer.

If required for proper understanding of the documents, additional descriptions/


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

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

Revised technical documents replacing previously submitted documents shall be


marked accordingly. Also, the revised part in the Document itself shall be marked
clearly with cloud mark.

2.2 Drawings

2.2.1 Loading Drawings


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

2.2.2 Foundation Drawings


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

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

If conduits are to be installed in the foundations, the relevant information such as


diameter, length, and purpose shall be indicated on the drawings.

2.2.3 Arrangement and Layout Drawings


All layout drawings shall be drawn to scale. The General Arrangement (Layout)
Drawings shall show the physical arrangement of Works (constructions, machines,
complete switchgears, control panels, instrument cubicles, etc.), civil constructions
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(buildings, rooms, foundations, ducts, etc.) and reserved areas (for pipes, cables, lines,
etc.) in relation to each other and to agreed coordinates and boundaries.

The Arrangement or Layout Drawings of electrical, instrumentation and control


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

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

2.2.4 Outline Drawings


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

2.2.5 Design Drawings


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

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

• Details of manufacturing and treatment of major single work pieces specially


manufactured for this Contract

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

• Sub-assembly of the principal components of the Works with overall dimensions,


adjustment and clearance tolerances, numbers of corresponding detail drawings

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

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

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

• Location and size of the instruments and accessories provided

• Methods of lubrication and sealing

• Instructions for heat treatment, pressure tests, surface preparation and anti-corrosive
protection
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• Full details of parts for which adjustment is provided or which are subject to wear

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

2.2.6 Installation Drawings


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

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

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

2.3.1 Single-Line Diagrams


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

Single-line diagrams of individual main components and switchboards shall additionally


show the control, indicating, measuring, metering, protection, automatic, and other
auxiliary electric devices (also limit switches, rheostats, hygrometers, etc.), separated
for each individual installation site and location.

2.3.2 Circuit Diagrams


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

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

Contact blocks of the installed switches, contactors, relays and other apparatus which
appear in the diagram shall be shown below the respective contactor coil, indicating by
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means of numbers and, if not on the same, also the page No., the current path in which
the corresponding contact has been used.

Interconnections to other circuit diagrams shall be clearly marked by means of dotted


line separations and the corresponding functional designation.

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

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

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

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

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

2.3.3 Block Diagrams


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

When recommendable, a Block Text Diagram may be prepared, consisting essentially


of explanatory texts enclosed in outlines which are linked by lines showing the
functional relationships that exist between the various parts of an installation, Works or
circuit.

2.3.4 Logic Diagrams


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

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


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2.3.5 Terminal Diagrams


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

The terminal diagram of each individual switchboard, terminal box, panel, etc., shall
contain, but not be limited to the following information:
• terminal number of terminal board with targets (terminal number and current path)
of incoming and outgoing cables and wires
• cable designation
• type of cable
• number and cross-section of conductors
• assignment of conductors
• number of spare conductors
• approx. length of cable and its destination.

2.3.6 Protection Coordination Diagrams


These diagrams shall show in a graphical manner separately for each power supply
circuit:
• a simplified single-line diagram of the circuit with technical data of all instrument
transformers and relays
• coordinated tripping curves of related protection devices
• setting of the protection devices.

2.4 Material Specification


Such specifications shall be prepared for all principal Works and installations. They
shall describe the performance (design, material, dimensions, corrosion protection, etc.)
of the Works and include a list of components providing information on the
manufacturer, type and technical data to obtain the following:
• full information on the Works, completing the general requirements fixed in the
Tender Specification by the data/information of the specific manufacture
• proof of compliance with Contract Specification

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

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


• max. permissible ambient conditions (temperatures, humidity)
• rated current and rated output/capacity
• same data as above under specified severest site conditions
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• rated voltage and ratio or regulation/setting range


• max. service voltage (acc. to IEC)
• power frequency and impulse withstand voltages
• type and code No. of protection relays and of instantaneous or thermal releases
directly attached to circuit breakers and contactors
• power requirements for each voltage level (AC/DC).

2.5 Lists and Schedules

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

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

2.5.2 Consumer (Motor) Data Schedule (MDS)


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

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

At least the following information/data are required for electrical consumers (if
applicable):
• Works identification number
• description
• manufacturer, type, rated data of driven machine
• manufacturer and type of electric motor/consumer
• rated capacity
• service factor (ratio between motor output and power requirement of the driven
machine)
• rated speed
• rated voltage
• rated current
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• ratio of starting current to rated current


• ratio of pull-out torque to rated torque
• power factor at rated capacity
• efficiency at rated capacity
• power consumption at machine design loading
• total weight
• design/enclosure/cooling (according to IEC)
• duty (continuous/intermittent/start-up)
• starting method/permissible starting frequency
• denomination of feeder
• motor protection
• applicable Standard Circuit Diagram
• maximum number and overall diameter of power cable(s)
• manufacturer and type of bearing(s)
• manufacturer, type and quantity of lubricant, service interval
• manufacturer, type, number, size, spring pressure and service interval of brushes (if
applicable).

2.5.3 Motor Starter Lists


The motor starter lists shall include all starters and contactors used for motors and
contain the following technical information as a minimum:
• Works identification number
• electrical design data as nominal and actual current rating, voltage rating, coil rating,
making and breaking capacity, mode of operation
• maximum power cable size
• maximum control cable size
• current transformer ratio, class and capacity
• type of protection relaying and catalogue number
• setting of protection relays and maximum continuous rating of the protected circuit
• type and current rating of the back-up fuses/MCB’s for the main and control
circuits.

2.5.4 Feeder Data Schedule (FDS)


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

• Consumer identification number and main characteristics


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• Designation and main outfit of corresponding feeder part in the MCC concerned
• Designation and description of proposed cable feeder connection between the MCC
and the corresponding consumer.

2.5.5 Cable Data Sheet (CDS) and Cable Laying Schedule (CLS)
The main cable data proposed respectively required by the Contractor shall be specified
by him in the enclosed sheets "CDS" and “CLS” and shall include for each individual
cable the following information as a minimum:
• cable number, in accordance with Identification System.
• cable type
• rated voltage
• number and size of conductors
• overall diameter
• cable termination at each end
• connection point at each end with cubicle/Works identification and terminal
numbers
• cable routing
• In case interconnecting cubicles are used, the lists shall be prepared to show:
• cable termination for incoming and outgoing cables
• interconnection wiring
A cable laying schedule shall be prepared by the Contractor as an instruction for
following activities on site:
• Selection of suitable cable type for the particular connection and description of
destination (on both cable ends).
• Terminal connection of cable cores (single wires) at both cable ends
(destination 1 + 2).
• Laying of the concerned cable in a suitable (existing) cable route.

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

2.5.6 Data Point List


The data point list shall indicate all control signals, process signals, measurement
signals etc., local as well as remote, and shall contain at least:
• denomination and description of signals
• signal type
• signal range
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• works identification number of source and receiver


• data of signal source and signal receiver
• information regarding how and where to proceed the data

2.5.7 Setting List


This list shall describe all settings, which either lead to warnings, alarms, fast shut
down, emergency shut down or characterize the system (such as time constants,
hysteresis, chosen orifice diameter in control circuits etc.). The setting list shall contain
at least:
• denomination and description of signals
• dimension
• setting value
• function

2.5.8 Alarm and Tripping List


This list shall summarize all signals which lead to warnings, alarms, fast shut down,
emergency shut down. The List shall contain at least:
• denomination and description of signals
• correlation of signals and warnings, alarms, fast shut down sequence and emergency
shut down sequence.

2.5.9 Workshop Test Schedules


Individual Workshop Test Schedules shall be prepared for Works/installations (such as
turbines, governors, valves, gates, pipes, bifurcation, cranes, hydraulic hoists, machines,
generators, transformers, switchgear, control gear, I & C systems, bus ducts, cables etc.)
and shall contain at least:
• Works identification number
• manufacturer
• place of manufacture
• place of test
• date of test
• objective of test (all individual tests)
• standards applied
• certification
• inspection (by Employer / Independent Test Authority / Contractor/ Subcontractor)
• release for shipment
• remarks
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On the above schedule or on separate sheets the Test Procedure shall be specified giving
for each test item (kind of test) a description, test method / Standards, used instruments,
sample/routine test, test judgment.

2.5.10 Site Test Schedules


Scope as in above article “Workshop Test Schedules”.

2.5.11 List of Tools and Appliances


Lists of Tools and Appliances shall detail for all tools and appliances included in the
scope of supply:
• item and code number
• description
• quantity
• weight where applicable
• gross storage requirements (separate for open-air, indoor, air conditioned) for
individual components

2.5.12 Spare Part Lists


Spare part lists shall detail for all parts included in the scope of supply:
• item and code number
• description
• quantity
• weight where applicable
• gross storage requirements (separate for open-air, indoor, air conditioned) for
individual components.

2.5.13 List of EDS Identification Numbers


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

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


0102, part 1, or IEC 60909 or 61660 for DC systems.

2.7 Installation and Commissioning Procedures

2.7.1 Installation Procedures


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

2.7.2 Pre-Commissioning Procedures


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

2.7.3 Commissioning Procedures


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

2.8 Operation and Maintenance Manuals

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

a) Table of Contents

b) List of Illustrations

c) Introduction

The Introduction shall contain:


• A brief general description of the Work items
• A brief description of the use of the Work items
• Definitions of technical terms used in subsequent graphs of the instruction book
• A complete list of all items used in accordance with the Works Identification
System.

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

b) Operating Principles and Characteristics

A brief summary of the technical operating principles of the Works, including


diagrams, circuit diagrams, sequence diagrams, piping, etc.

c) Operating Instructions

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

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

d) Testing and Adjustment

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

e) Maintenance Instructions

This section is divided into five paragraphs:

• Preventive maintenance, indicating the inspections required at regular intervals,


the inspection procedure, the routine cleaning and lubricating operations, the
regular safety checks and similar steps.

The maintenance instructions shall include a tabular (or in other approved form)
summary of the required activities sorted according to
• daily
• weekly
• monthly
• quarterly
• yearly
• (or other) cycles as applicable.

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

• Repair and adjustment, describing the inspections, fitting and dismantling of


parts, fault tracing as well as repair and adjustment procedures.

• Spare part lists, containing all the necessary data for ordering spare parts. These
lists shall include all spare parts; those to be supplied and those not to be
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supplied under the present Contract. The prices for each spare part (exceeding a
unit price of EURO 100 or approximately 120US$) shall be indicated in the list.

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

• List of suppliers and alternative suppliers and addresses.

f) As-built drawings.

2.8.2 Format and Compilation


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

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

The main text shall be on white paper

The paper used in the final version of the O & M manual shall be of the following
archival quality material:
− White sheets: 70 g/m² to 106 g/m2;
− Colored sheets: not less than 70 g/m2.

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

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

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

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

2.8.3 Revisions and Supplements


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

• Deletions

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

• Corrections, Revisions, Replacements

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

• Insertions, Supplements

Insertions or supplements shall be accompanied by a new respective "Table of


Contents" page, where the latter shall be handled as described above under
replacements.

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

Before issuing the "Taking-Over Certificate" as per General respectively Particular


Commercial conditions of contract, the revised copies of the Operation and
Maintenance Manual shall be submitted together with the specified number of complete
sets of drawings of the Works as completed. The Works shall not be considered
complete for purposes of taking over under the terms of the Commercial conditions of
contract until the above documents have been supplied by the Contractor.

2.9 Progress Reports during Design and Manufacturing


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

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

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

• The total overall percentages of design and manufacturing completed, with reference
to the Contractor's Construction Program (CP). Appropriate comments shall explain
any differences.
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• A list of activities scheduled to be started within the next period of two (2) months,
with expected starting and completion dates. If the expected starting and/or
completion dates are different from those shown on the CP, an explanation shall be
given.

2.10 Test Reports During Manufacturing


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

2.11 Progress Reports During Installation at Site


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

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

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

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

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

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

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

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

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

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

• A statement detailing the status of progress on the overall program and how to
regain any lost time or set-backs which may have occurred.
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• A list of inoperable temporary equipment, and the estimated date when the repair
will be completed.

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

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

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

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

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

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


be resolved.

2.12 Test report during installation on site


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

2.13 Commissioning Report


The commissioning report shall contain all relevant test results, diagrams, settings and
characteristic system data.
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3 SPARE PARTS AND TOOLS

3.1 Spare Parts


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

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

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

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

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

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

3.1.1 Specified Spare Parts


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

3.1.2 Recommended Spare Parts


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

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

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

3.2 Tools and Appliances


The tools, wrenches, etc. shall be unused. Customary tools for erection shall be of the
forged and polished chrome-vanadium type. Use of special tools and devices for
erection shall be allowed, but shall be approved by the Employer in each case. Special
tools and devices shall be provided with means for ready identification.
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All lifting devices and wire ropes slings to be used at site shall be tested at works and
test certificate shall be supplied to the Employer.

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

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

4.1 Design and Construction Requirements


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

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

The Works shall be designed, manufactured, arranged and installed to provide


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

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

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

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

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

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

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

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

Suitable lifting eyes and backing-out bolts shall be provided where required or where
they will be useful for erection and dismantling.
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Pockets and depressions likely to hold water shall be avoided, and if not avoidable they
shall be properly drained.

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

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

4.2 Allowable Stress

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

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

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

Static loads

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

For uniformly distributed stresses:

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

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

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

For maximum local stress peak

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

Dynamic loads

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

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

Definition of operational loading cases

The operational loading cases are defined as follows:

a) Normal operation means operation under load up to maximum permissible


continuous output under maximum head, taking into account the effects of the
water hammer and of the speed rise after load rejection under the most adverse
combination of operating conditions.

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

c) Extreme load case means the pressure test etc.

4.2.3 Standard equipment


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

4.2.4 Hoisting equipment and steel structures


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

4.3 Design Criteria


The plant equipment shall be designed for the worst of possible combination of the
following loading conditions:
• All static and dynamic hydraulic loads,
• Forces due to short-circuits,
• All loads due to dead weight and frictional forces,
• Seismic or wind loads
• Thermal load and
• Other loads
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4.3.1 Seismic Loads


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

Moreover vertical and horizontal acceleration shall be combined in the most


unfavorable way. For horizontal and vertical accelerations values stated in “Information
for Tenderers” have to be observed.

Stresses resulting from these loads shall not exceed permissible stresses.

4.3.2 Wind Load


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

For plane surface: 1.2

For a cylindrical surface: 0.7

For lattice member, at front side: 1.6

For lattice member, at rear side: 1.2

4.4 Standardization of Works


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

The Employer, therefore, reserves the right to request the different contractors to use
uniform types or makes of Works and materials. The Contractor shall not be entitled to
claim extra payment due to this request. This request shall especially be applicable to
small mechanical and electrical Works such as:
• valves
• thermometers
• pressure gauges
• flow meters
• water level gauges
• sight flow indicators
• terminals and terminal racks
• indicating instruments and meters
• auxiliary relays
• LV circuit breakers, contactors, fuses
• motor protection switches
• control devices
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• lights, bulbs, plugs, sockets

4.5 Noise
The noise level caused by the installed Works shall not exceed the following values if
not otherwise stated in the PTS:
• Machine hall, workshops, etc. max. 90 dB (A) at any place 1 m distant from
operating equipment.
• Offices, control rooms max. 55 dB(A)

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

4.6 Identification Plates and Labels

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

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

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

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

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

4.6.2 Manufacturer's Nameplates


The following data shall be shown in accordance with the relevant standards:
• manufacturer's name and address
• Work's serial number and date of manufacture
• main design data.

As a general rule, standardized components, such as small or medium-sized electric


motors, transformers, instruments, etc., may be delivered with the manufacturer's
standard nameplate which shall be completed or replaced at the request of the
Employer.
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The design of the Manufacturer's nameplates for the main components such as gates,
valves, hoists, servo motors, pumps etc., shall be submitted for the Employer's approval
sufficiently in advance.

4.6.3 Identification Plates


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

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

4.6.4 Instruction Plates


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

4.6.5 Warning Plates


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

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

4.6.6 Labels for Conduits, etc.


Conduits have to be labeled where required.

4.6.7 Labels for Cables


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

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

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

4.6.8 Rating Plates


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

4.6.9 Single-Line Diagrams


Each switchgear room shall be furnished with a copy of the final as-built single-line
diagram detailing all electrical data and denominations, separate for each individual
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switchgear / distribution board / MCC, placed under glass and frame/wall mounted at an
approved location.

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

4.6.10 Key System for Electric Boards


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

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

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

4.7 Corrosion Protection

4.7.1 Painting

4.7.1.1 Scope of Work


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

4.7.1.2 Painting Materials


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

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

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

Paint material shall be delivered in unopened original containers bearing the


manufacturer's brand name and color designation, storage directions and handling
instructions. A complete list of the proposed paint material shall be submitted to the
Employer.

With regard to materials, the Contractor shall submit full details including the source of
the basic raw materials, volatile matter content, nature of solvent, number of
components, type of coat, coverage, time interval between coats and number of coats,
compatibility of each coat with the previous coat, toxic properties, physical properties,
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shelf life, resistance against chemical attack, resistance against ozone and UV-radiation,
compatibility with drinking water standards, etc.

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

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

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

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

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

4.7.1.3 Workmanship

(1) Contractor's Equipment

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

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

(2) Preparation of Paint Material

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

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

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

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

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

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

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

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

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

Relative Humidity Time

85% or above Do Not Blast


80 - 84% 2 hours
70 - 79% 4 hours
60 - 69% 10 hours
50 - 59% 12 hours
30 - 49% 24 hours
under 30% 1 Week

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

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

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

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

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

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

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

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

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

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

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

In linings surrounded by concrete, surface preparation and painting works shall be


carried out after all Works such as concreting, welding, grouting and cleaning have been
completed. The Contractor shall take into account the local climatic conditions and use
adequate installations for sandblasting, dust control and sand extraction.

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

The minimum dry-film thickness prescribed in these Specifications shall be observed.


No measured thickness shall be less than the specified thickness. Where the minimum
thickness is not achieved, the coat shall be repaired to reach the specified minimum dry-
film thickness.

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

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

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

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

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

(6) Guarantee

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

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

4.7.1.4 Painting Systems


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

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

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


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

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


recognized standards.

4.7.1.6 Repair of Primer and Finish Coats


(1) General

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

(2) Galvanized and Painted Structures

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

Damages to painting and galvanization:


• Surface Preparation: Scraping, wire-brushing or grinding to Grade ST 3 according to
SIS 055 900-1967.
• Repair of Coatings: One coat of 2-component epoxy resin zinc-chromate primer.
Dry film thickness minimum 0.050 mm.
• Two coats of 2-component epoxy-resin micaceous iron oxide (mio) paint. Total film
thickness min. 0.160 mm. The color of the paint shall be the same as originally
applied.

Damage to Painting only:


• Surface Preparation: Thorough cleaning of the damaged surface i.e. removal of oil,
grease, dust, etc.
• Repair of Coatings: Two coats of 2-component epoxy-resin micaceous iron oxide
(mio) paint. Total film thickness min. 0.160 mm.
• The color of the paint shall be the same as originally applied.

(3) Painted Structures

Repairs on painted structures shall be carried out as follows:


• Surface Preparation: Scraping, wire-brushing or grinding to Grade ST 3 according to
SIS 055 900-1967.
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• Prime Coat: One coat of 2-component epoxy resin zinc-chromate primer. Dry film
thickness minimum 0.050 mm.

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

Galvanizing shall be performed in accordance with VDE Standard 0210 (Verband


Deutscher Elektrotechniker).

(1) Material

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

The thickness of the zinc coat shall be:


• for bolts and nuts, approx. 60 micrometer
• for all other parts, except for hydraulic steel structures or parts intermittently or
permanently submerged in water, approx. 70 micrometer
• for hydraulic steel structures or parts intermittently or permanently submerged in
water, approx. 140 micrometer, in accordance with "VDEW, Druckrohrleitungen -
Association of German Electricity Utility Companies, Steel Penstocks".

(2) Cleaning

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

(3) Galvanizing of Hardware

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

(4) Straightening after Galvanizing

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

(5) Repair of Galvanizing

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


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

Surfaces to be machine-finished shall be indicated on the shop drawings by symbols.


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

4.7.4 Unfinished Surfaces


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

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

4.7.5 Protection of Machined Surfaces


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

4.7.6 Rounding, Chamfers, Edges


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

4.8 Welding and Heat Treatment

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

The Contractor shall submit with his Tender adequate information concerning the
proposed:
• extent to which automatic welding techniques will be applied;
• extent to which manual welding techniques will be applied;
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• extent to which it is the Contractor's intention to use pre-weld heat treatment, post-
weld stress relieving, full anneal stress relieving or normalizing consistent with the
thicknesses and types of material proposed;
• weld electrodes, welding wire and flux which will be used with the selected plate
material or materials;
• standard tolerances for the deviations of mating weld profiles.

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

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

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

Wherever welding is specified or permitted, a welding process approved by the


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

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

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

The Contractor shall follow the steel manufacturer’s recommendations concerning


electrodes, welding and material pre- and post heat treatment. Notwithstanding the
above, the suitability of the electrodes to be used for welding and the welding methods
to be used for both shop and field welding shall be demonstrated by trials and tests to
the satisfaction of the Employer.

Additional copies of all records of all welding procedures, including preheating and
stress relieving, chemical analysis and physical properties, shall be made available to
the Employer upon request.
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Design, preparation, performance and testing of welded constructions shall suit the kind
of stresses and the grade of risk, considering a supposed failure of the welded member.

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

STRESS

Compression Bending, Tension Alternating,


>0.9 allowable Dynamic
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

0= Without special prescriptions. Only skilled welders shall be employed which


follow proven rules of workmanship.

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

2= Welder qualification test. All welders and welding operators shall have passed
qualification test in accordance with the respective National Standard or rules of
AWS-American Welding Society, or the DIN EN 287.
Weld ground flush. The weld shall be ground on both sides of the steel plate. The
weld surface shall be finished so as not to reduce the plate thickness by more than
3%. Butt welds with a smooth surface and a chamfer of less than 8% of the width
of the top layer need not be ground.
Connections rounded. Where stresses are to be deviated, already the design shall
care for a reduced notch effect. Welds shall be smoothly ground and rounded.

3= Welding procedure test. The Contractor shall describe the proposed welding pro-
cedure. Further he shall prove with tests, that the properties of the weld and
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transition zone are at least equal to those specified for the base material. The
welding procedure test may be combined with the welder's qualification test.

4= Welding performance test, executed during fabrication and site welding. Run-off
plates shall be tack-welded to one end of the plate under work. The weld shall
continue on that run-off plate (test plate), welded in the same manner and under
normal working conditions.
• One test plate is required every 20 m of weld seam, but at least one of each
weld type.
• The laboratory tests shall cover the same range as the welding procedure tests.
• On request by the Employer test plates shall be welded in his presence.

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

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

4.8.3 Welding Qualifications


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

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

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

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

4.8.4 Welding Work


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

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

Between plates and other sections where such stresses are to be transmitted only butt
welds shall be permitted. All main butt welds shall have 100% penetration and where
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possible, shall be welded from both sides. The backside of the first run shall be suitably
gauged out to clear metal before the sealing runs are deposited.

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

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

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

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

Tacks shall be removed before welding.

Electrodes shall be dried in electric ovens before use.

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

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

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

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

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

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

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

The ignition of weld electrodes shall not be started at the plate beside the weld, but at
the seam flanks to prevent detrimental increments of local hardness. Where ignition
points of electrodes are discovered, they shall be ground appropriately.
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Where auxiliary structural members are welded to components for the purpose of
assembly or installation, these connecting welds shall be given particular care.

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

4.8.5 Heat Treatment


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

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

4.8.6 Quality and Procedure Control


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

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

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

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

The following or other equivalent Standards shall apply:

• for radiographic examination:

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


Metallic Materials

DIN 54111 Non-destructive Testing; Testing of Welds


of Metallic Materials by X- or Gamma Rays;
Radiographic Techniques

DIN EN 287 Quality Assurance of Welded Structures;


Fusion-welded Joints Steel; Requirements Classification

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

• for ultrasonic examination:


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• According to the approved "Test and Examination Instructions" of the Contractor


based on AD-leaflet HP 5/3.

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

Additional non-destructive controls can be required when it is desired to examine the


acceptability of any welds when, in the opinion of the Employer, serious doubt exists as
to their quality; in this case, the expense of this examination shall be borne by the
Contractor.

When required in the Particular Technical Specifications, the detailed description of


welding procedure (including type of welding electrodes, sequence of welding seams,
etc.) for certain parts of the delivery shall be submitted to the Employer before
commencement of manufacture.

4.8.7 Defects and Repairs


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

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

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

The Work shall be 100% inspected again by the method used first to determine such
faulty work.
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5 MECHANICAL WORKS, METAL AND STEEL STRUCTURES

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

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

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

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

Revolving parts shall be statically or, if required in the Particular Technical


Specifications, dynamically balanced so that when running at normal speed and at any
speed up to the maximum, there will be no vibration due to lack of balance.

5.2 Bolts, Screws, Nuts, etc.


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

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

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

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

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

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

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

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

5.4 Protection Guards


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

5.5 Drives and Gears


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

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

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

5.6 Lubrication, Lubricants, Fuel


Efficient means of lubrication, suitable for use under Site conditions, shall be provided
for all moving parts.
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Self-lubricating types of bearings shall be given preference, unless otherwise specified


or practicable.

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

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

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

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

5.7 Piping, Fittings, Valves and Gates

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

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


slip-on flanges.

Welding as well as application of corrosion protection coats shall be done in the


manufacturer's shop to the greatest extent possible.

Flanged connections or joints shall be provided only as required for transport,


installation or for reasons of dismantling for repair.

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

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

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

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

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


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5.7.2 Water Piping and Fittings


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

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

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

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

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

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

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

5.7.3 Valves, Gates


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

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

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

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

To facilitate operation, large valves and gates shall be provided with by-pass lines for
pressure balancing, if required.
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All valves shall be readily accessible for both operation and maintenance, and where
necessary for ease of operation the spindles shall be extended and an approved form of
pedestal hand-wheel provided at convenient operating floor level.

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

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

5.7.4 Oil Piping


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

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

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

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

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

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

5.7.5 Pipe Supports and Hangers


All pipework and accessories shall be mounted and supported in a safe and neat manner.

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

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

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

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


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

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

5.9 Pressure Oil Systems


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

Oil sump tanks shall be provided with:


• suitable access openings
• fine mesh strainer combined with a magnetic filter through which all oil returning
from the servomotors shall pass. The strainer shall be readily removable for
cleaning.
• dehumidifying air filter
• flush-mounted oil-level indicator
• filling connection with a suitable strainer
• drain connection with hand operated shut-off valve.
Sump tanks shall be installed so that the bottom of the tank and the drain connection are
at least 40 cm above the floor. The bottom of the tank shall be inclined in the direction
of the drainage. The pumps shall be removable without the necessity of emptying the
tank.

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

5.9.1 Hydraulic Pressure Units


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

5.9.2 Manufacturing and Tests


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

ƒ Oil tank tightness shall be tested.

ƒ 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
ƒ It shall be possible to isolate any pressure generating device (pump, pressure
vessel, cylinder, etc.) from the pipe-work by means of lockable valves.

ƒ Large oil tanks shall include a manhole.

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

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

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

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

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


ƒ Kinematic viscosity at 50 C, in cSt,
ƒ Engler viscosity, in °E,
ƒ Total acid index, in mg KOH/g,
ƒ Solid impurities content, in %,
ƒ Water content, in %,
ƒ Flash point, in C,
ƒ Solidifying temperature, in C.
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The following table establishes the general quality requirements:


Oil Application Total Acid Index Water Content Kinematic Viscosity Solid Contamination

in mg KOHg % in Vol. at 40 C in cSt

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

Foaming : In all cases to be visually monitored

The Contractor is responsible to ensure that the properties of the delivered oil do not
exceed the threshold value.
If the threshold value is exceeded the Employer shall reserve the right to request either
complete refill with the corresponding oil, or treatment of the oil and cleaning of the
affected system, at Contractor’s expense.

5.9.6 Oil Tests


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

5.10 Compressed Air Systems


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

Vessels shall be of the cylindrical type and shall be mounted on a structural steel base.
The inner surfaces of the vessels shall be protected with an appropriate paint coating or
the vessels shall be hot dip galvanized. Each vessel shall be equipped with the following
devices:
• 2 inlet sockets with valves
• 2 outlet sockets with valves
• 2 pressure safety valves
• 2 dial pressure gauges, one of the gauges with 4 electrical contacts
• 1 manhole or inspection hole
• 1 drain valve.
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In case the pressure vessel is used for pressurized oil or water systems, the vessel shall
further be equipped with:
• 1 transparent level gauge with shut-off valves at both ends
• level indicators with electrical contacts in a number as required or specified.

Compressors shall be provided with:


• automatic lubrication
• air-intake filter and silencer
• thermometer for measuring temperature of the compressed air
• automatic shut-down if the discharge air temperature exceeds a predetermined,
adjustable value
• discharging valves
• water drain valves
• water/oil separator
• pressure safety valve
• compressed air cooler
• non-return valve
• inlet pressure valve
• outlet pressure valve
• automatic moisture trap

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

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

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

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

Each vessel shall be furnished with a test certificate of an independent, reputable


underwriters' society.

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

casing cast iron (C.I.)


impeller bronze / stainless steel
shaft stainless steel
sleeves stainless steel
wear rings Bronze
keys stainless steel

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

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

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

Each pump shall be fitted with:


• check valve at the discharge side
• air and drain valve
• pressure gauge.

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

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

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

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

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

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

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

5.12 Lifting Equipment

5.12.1 Design and Calculation Standards


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

Design FEM rules for design of hoisting appliances 1998 (Fédération


Européenne de la manutention)
CMAA, Crane Manufacturer's Association of America

ISO 4301-5: 1991, Cranes Classification; Part 5: Overhead


traveling and portal bridge cranes.

ISO 7752-5: 1985, Controls-Layout and characteristics, Part 5:


Overhead traveling and portal bridge cranes.

ISO 8566-5: 1992, Cranes - Cabins, Part 5: Overhead traveling


and portal bridge cranes.

ISO 10245-5:1995, Cranes - Limiting and indicating devices Part


5: Overhead traveling and portal bridge cranes.

ISO 4308-1,1986, Cranes and lifting appliances- Selection of wire


ropes, Part 5: Overhead traveling and portal bridge cranes.

ISO 4302: 1981, Cranes - Wind load assessment

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

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


combinations.

DIN 15018, Cranes, Steel Structures, Calculation and Design

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

ISO 4310: 1981, Cranes - Test code and procedures

DIN 4100, Welded Steel Structures

DIN 15020, Rope Drives Safety devices for the operating


personnel

Safety devices for the operating personnel shall be provided wherever it is deemed
necessary.
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The safety rules outlined in VBG 8 of the German "Verband der Berufsgenossenschaft"
or similar internationally recognized codes shall be observed.

Unless otherwise specified, the lifting equipment shall be classified to DIN 15020 as
follows:
• for lifting capacity up to 100 kN (10 tons) "class 2 m", representing an average daily
working time of 2 to 4 hours and an equal share of small, medium, and heavy loads
(normal duty);
• for lifting capacity above 100 kN (10 tons) "class 1 Am", representing an average
daily working time of 2 to 4 hours and a small share of heavy load lifts (light duty).

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

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

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

Steel structures of lifting equipment shall be of welded construction, which can be


assembled at Site. All field connections and joints shall be bolted.

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

5.12.2 Material Standards


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

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

5.12.3 Admissible stresses


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

mean allowable compressive stresses 6 MPa

allowable compressive stresses on edges 10 MPa

allowable bond stresses 0.6 MPa


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5.12.4 General Design Particulars


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

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

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

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

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

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

All sleeve bearings except those for the hooks and rope sheaves shall be lubricated by
central lubrication systems. An independent system for the trolley and one or two
independent systems for the bridge will be acceptable. This central lubrication system
shall satisfy the following requirements:
• the lubricant quantity for each bearing shall be variable
• lubricant filters shall be installed in every lubricating pipe
• the lubrication piping shall be arranged to be easily accessible for maintenance

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

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

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

5.13 Steel Structures


Generally, design and stress calculation shall conform to:

DIN 1050 Steel Structures, Construction

DIN 4100 Welded Steel Structures, Calculation and Design


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DIN 4114 Stress Calculation of Steel Structures

DIN 18800 Steel Structures, Calculation and Construction

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


Equipment".

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

Adequate clearance of at least 2 m shall be provided at overhead steel structures to


allow unobstructed passage.

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

Vertical ladders shall be installed alternating left hand/right hand side to horizontal
platforms placed approx. every 10 m of vertical height. Vertical ladders of more than
2.5 m height shall be guarded. Load assumptions for ordinary platforms shall be:
• for platforms used by personnel and for support of light equipment with single
weights of less than 500 N: 2,500 N/m2
• for all other platforms 5,000 N/m2
unless otherwise specified or stipulated in the applicable standards.

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

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

5.14 Hydromechanical Equipment- Design and Manufacture

5.14.1 Selection of Equipment


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

The following types are normally applied:


Regulating and sluiceway gate Radial gate, flap gate, fixed wheel gate
Intake and culvert gate Fixed wheel gate or slide gate
Navigation lock gate Miter gate
Navigation lock gate for passage of flood Sector gate
Stoplogs, bulkheads Slide gate
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5.14.2 Design Loads


The equipment will be designed to withstand the worst possible combination of loads
considering the operating condition and the frequency of operation, etc. Loads to be
considered are as follows:
• Hydrostatic load: Hydrostatic load shall be the water head difference between the
upstream and downstream sides of the gate, trash rack or stoplogs.
• Dead weight
• Wave height due to wind
• Sediment load
• Wind load
• Operating load
• Water pressure variation and vibration force induced by flowing water: Water
pressure variation and vibration force induced by flowing water will be considered.
The gate shall be capable of operating satisfactorily without vibration under any gate
opening and conditions of water flow.
• Wave height due to earthquake
• Dynamic water pressure during earthquake
• Inertia force during earthquake: The Inertia force during an earthquake shall be the
multiplication of the dead weight by the seismic intensity.
• Temperature loads: The effect of solar heating shall be taken into consideration.

5.14.3 Allowable Stresses


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

5.14.4 Corrosion Allowance


A corrosion allowance is not required.

5.14.5 Skin Plates


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

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

for other gates and inspection gates 10 mm,


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5.15 Gate Hoists

5.15.1 Operating Load


The operating load of the hoist is the sum of the self-weight of the gate leaf, the self-
weight of ballast if any, the friction loads due to the rolling, bearing and sealing parts,
and other loads as follows:
• Dead weight of the gate leaf and/or ballast weight,
• Friction force due to rotating and/or sliding parts,
• Friction force due to seal rubbers,
• Buoyancy,
• Uplift force and down pull force,
• All loads resulting from the maximum torque of hoist motor under gate jammed
conditions.
• Loads due to the action of earthquake according to Clause 3.2.1.2.

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

5.15.2 Allowable Stresses


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

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

where, F minimum breaking strength of wire rope


L normal tensile force acting on wire ropes
N number of wire rope falls to be used

5.15.3 Operating Speed


For general use 0.25 - 1.0 (m/min)
For emergency closure gates, like power-intake 2-3 (m/min)

5.15.4 Motor Output


The capacity of all electric motors is to be more than that calculated from the following
equation.
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W⋅v
Output =
6.12 ⋅ η
[kW ]

where, W operating load (tones)


v operating speed (m/min)
η total efficiency obtained by multiplying respective efficiencies of
the mechanical parts as given below.

Table 3.2: Efficiencies of Mechanical Parts

Item Mechanical parts Efficiency

1 Drum 0.95

2 Sheave (plane bearing) 0.95

3 Straight & helical gear 0.95

4 Bevel gear reducer 0.80 - 0.85 with

5 Worm gear reducer 0.50

6 Oil-hydraulic hoists 0.85

* Friction coefficient

- Spindle screw 0.2

- Worm gear screw 0.06 - 0.1

5.15.5 Diameter of Wire Drum and Sheave


The minimum drums and sheaves diameters for gate hoists are to be as follows:
• 25 - 32 times diameter of wire rope for drum
• 14 - 16 times diameter of wire rope for sheaves

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

5.15.6 Oil Hydraulics


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

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

5.15.7 Leakage of Gates


Water leakage under any head and without the use of any additional sealing materials
per m length of gasket:
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• for gates 0.1 l/s per m length of seal


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

5.16 Cranes and Lifting Equipment for Gates

5.16.1 Design Loads


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

• In service or operating condition:


• Dead loads due to dead weight.
• Live loads including the hook load multiplied by an impact factor of 1.3.
• Horizontal loads due to inertia and skew loads due to traveling.
• Wind loads during operation. For outdoor cranes, the in service design wind
loads according to Clause 3.2.1.2 shall be applied.
• Loads due to collision with buffers.
• Loads due to the action of earthquake according to Clause 3.2.1.2.

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

• Out of service condition:


• Dead loads due to dead weight
• Storm wind load. For outdoor cranes, the storm wind pressure will be
1,250 N/m².

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

5.16.2 Allowable Stresses


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

5.16.3 Operating Classification


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

5.16.4 Wire Ropes


The factor of safety of wire ropes is to be 6 based upon the minimum ultimate strength
of the wire ropes.
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5.17 Quality of Materials and Equipment


For general requirements concerning the quality of materials and Works refer to the
General Conditions.

No welding, burning, filling or plugging of defective castings or any other defective


components shall be permitted without the Employer’s agreement in writing. The
repairing work shall be in accordance with ASME VIII Boiler and Pressure Vessel
Code, Appendix 7, Examination of Steel Casting, Section 7-4 Repairs, Item D.

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

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

5.17.1 Material Preparation

5.17.1.1 Material Identification


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

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

5.17.1.2 Cutting and Edge Preparation


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

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

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

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

5.17.1.3 Forming of Curved Plates


Curved plates and section shall be formed to the correct curvature by cold rolling
without reducing the yield strength of the material. The procedure shall be approved by
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the Employer. The limit on the amount of strain induced by the cold process shall be
3 %. The finish product shall meet the requirements of the Committee Européen de la
Chaudrainerie et de la Tôlerie (CECT) or BS 4360.

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

5.17.2 Spacing of Seams and Splices

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

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

Splices shall be arranged to minimize overhead welding. Spliced materials of different


widths and thickness shall have smooth transitions.

Lapped joints are not permitted.

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

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

5.17.3 Laying-out, Alignment and Fit-up

5.17.3.1 Laying-out
At all stages during fabrication, the Contractor shall ensure correct positioning,
alignment and levels in accordance with the required data.
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Overloading, damage or any permanent deformation of any of the structural components


at any stage of the erection shall be rectified in accordance with a procedure approved
by the Employer.

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

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


welds.

5.17.3.2 Alignment and Fit-up for Welding and Tack Welding


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

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

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

5.17.3.3 Temporary Attachment Welds


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

5.17.3.4 Cope Holes


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

5.17.4 Temporary and Non-structural Attachments and Cut-outs

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

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

Temporary attachments and cutouts are not permitted at steel liners and steels exceeding
500 MPa yield strength.
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5.17.4.2 Removal
The removal of temporary attachments shall be either by thermal cutting or by grinding.
If thermal cutting is employed, the attachments shall be cut off at a minimum distance
of 5 mm from the surface of the material and then ground flush. Following removal, the
area of the attachment weld shall be subjected to 100 % magnetic particle inspection.

Temporary attachments shall not be removed by hammering, or by any other technique,


which may cause mechanical damage to the surface of the steel forming the main
structure.

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

5.17.4.3 Temporary Cut-Outs


The need for temporary cutouts shall be subject to approval by the Employer.

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

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

5.17.5 Finishing of Surfaces


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

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

5.17.6 Repair and Remedial Procedures

5.17.6.1 Repair Welding


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

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


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

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

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

Straightening procedures, which will include full details of methods of monitoring


temperatures and times, are to be submitted to the Employer for approval prior to
straightening. Methods of assessing the extent of any damage to the parent material by
straightening are to be included in the proposals.

Hammering shall not be permitted.

5.17.7 Temporary Fabrication Aids


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

Additional precautions shall be taken to ensure that miscellaneous projections such as


pipes, pipe supports, nozzles, etc. are fully protected from interference with lifting
slings during installation.

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

Proper accounts shall be taken of the effects of differential deformation of support


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

5.17.7.1 Temporary Bracing and Supports


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

Adequate temporary bracing shall be provided and shall be left in position until such as
the structure is sufficiently far advanced for the bracing to be no longer required.
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5.17.7.2 Rectification of Surface Defects and Edge Laminations


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

5.17.7.3 Erection Loads and Stability


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

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

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

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

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

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

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

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

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

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

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

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

Outdoor installations shall be protected against solar radiation by means of adequate


covers, where required.

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

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

Low Voltage (LV) up to 1kV AC

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

High Voltage (HV) > 36 kV AC

6.2 Standards
The design, manufacture and testing of all Works and installations shall strictly comply
with the latest edition of the relevant IEC publications.
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Regulations IEC 60364 for Electrical Installations of Buildings shall be compulsory.

6.3 Operation Voltage and Characteristic


The following ratings refer to the values at the respective distribution boards.

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

6.3.1 Low Voltage AC Power System

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

Nominal voltage between phases and 230V +10% / -15%


neutral

Frequency 50Hz + 4% / - 6%

Grounding system Neutral point solidly


grounded

6.3.2 Direct Current and Uninterrupted Power Supply UPS

6.3.2.1 220V DC System

Nominal Voltage 220V DC +/- 15%

System configuration 2 wire – high resistance


middle point grounding

6.3.2.2 110V DC System

Nominal Voltage 110V DC +/- 15%

System configuration 2 wire – high resistance


middle point grounding

6.3.2.3 48V DC System

Nominal Voltage 48V DC +/- 15%

System configuration 2 wire – high resistance


middle point grounding
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6.3.2.4 400/230V Uninterrupted Power Supply System

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

Nominal voltage between phases and 230V +10% / -15%


neutral

Frequency 50Hz + 4% / - 6%

Grounding system Neutral point solidly


grounded

6.4 Electric Motors

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

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

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

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

6.4.2 Motor Voltages and Power Ratings


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

Motors up to 100 kW:


Service voltage 3-phase 400/230 V AC
Mode of starting direct on-line up to 50 kW
above 50 kW with suitable starters

Motors up to 0.75 kW:


Service voltage single-phase 230 V AC
Mode of starting condenser

Motors intended to work on the DC system:


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Service voltage 220 V DC

Mode of starting Resistor

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

Power Demand of Driven Machine Service Factor


Up to 5 kW 1.2
More than 5 kW 1.1

AC motors shall be capable of operating continuously under rated output conditions


within the voltage variation range and / or frequency variation rage as specified in
Chapter 6.3

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

DC motors shall be capable of operating continuously under rated output conditions


within the voltage variation range with a fixed brush setting for all loads. Unless
otherwise approved, the speed drop between no-load and full-load shall not exceed 10%
of no-load speed.

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

The maximum starting currents (without any tolerance) shall not exceed the following
values:
• 3 times rated current for AC motors rated above 50 kW
• 2 times of rated current for DC motors

Generally, all motors shall be able to withstand three cold starts per hour, equally
spaced. In addition, each motor shall be capable of withstanding three successive starts
with the motor initially at operating temperature or once every twenty minutes without
detrimental heating.
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Motors for frequent automatic starting shall have an adequate rating. In the motor data
sheet MDS the Contractor shall state the frequency of starts permitted in compliance
with the motor design.

6.4.5 Windings and Insulation Class


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

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

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

6.4.6 Ventilation and Type of Enclosure


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

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

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

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

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

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

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

Vertical motors shall have approved thrust bearings.

Where sleeve bearings are being used, they shall be of the self or forced lubricating
type. If forced lubrication is required, it shall be arranged common to both the motor
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and the driven machine and provisions shall be made to ensure lubrication during start-
up and shut-down operations without the necessity to start an auxiliary lube oil pump.
Self-lubricated bearings shall be equipped with an easily accessible oil reservoir with
overflow pipe and oil collecting vessel.

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

In case of independent bearings, motor and bearing pedestals shall be fitted on a


common base plate.

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

6.4.8 Shafts and Couplings


The motor shall be balanced together with the motor side coupling.

6.4.9 Brushgear and Commutators


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

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

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

6.4.10 Terminal Boxes and Grounding


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

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

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

Terminal boxes shall be totally enclosed and designed to prevent the ingress of moisture
and dust. All joints shall be flanged with gaskets of neoprene or similar material. For
motors above 1 kW, the terminal box shall be sealed from the internal air circuit of the
motor.
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Depending on the size, the terminal box of motors shall be fitted either with an
approved cable sealing-end or with a gland plate drilled as required and provided with
suitable fittings for cable fixing and sealing. Such openings shall be temporarily
plugged or sealed during transportation.

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

6.4.11 Measuring and Monitoring


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

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

Vibration displacements or velocity shall be measured in accordance with DIN 45 665


for IEC motor sizes 80 to 315. The results for all motors shall be within the "R"
(reduced) limits.

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

Workshop Tests:

Motors up to 50 kW
• Measurement of winding resistance
• Measurement of insulation resistance
• No-load measurements

Motors rated 50 kW and above


• Measurement of winding resistance
• Measurement of insulation resistance
• No-load and short-circuit measurements
• Measurement of starting current and torque
• Efficiency measurement (type test)
• Heat test run (type test on motors rated 50 kW or higher)

Site Tests:
• Measurement of insulation resistance
• Measurement of electrical values such as (starting) current, voltage
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• Measurement of motor vibrations (on motors rated 50 kW or higher)


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

6.5 MV and LV Switchgear, Cubicles and Panels

6.5.1 General Design and Construction Features


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

The equipment shall meet the applicable IEC Recommendations.

Electrical switchboards shall be constructed of braced rolled steel sections, with


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

Item Min thickness [mm]

Panel rack 1,5mm

Doors 2,0 mm

Backplane 1,5 mm

Roof 1,5 mm

Mounting plate 3,0 mm

Floor plates 1,5 mm

Where required, (e.g. in case of heavy, flush-mounted equipment in a door) the


thickness of the specific part has to be increased appropriately.

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

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

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

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

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

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

The switchgear shall be of the indoor, completely enclosed (protection class IP 42),
metal-clad type with draw out or fixed mounted switching.
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The construction shall be such that the various compartments of the switchgear are
segregated electrically from each other; it shall be possible to gain access to the circuit
breaker and to the cable box chamber in any cubicle without having to take the busbars
out of service. Hinged doors and bolted panels shall be provided.

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

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

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

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

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

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

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

Busbars shall be made of high conductivity electrolytic copper suitably protected


against corrosion and rigidly supported on approved type of insulators.

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

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

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

All switchgear, busbars and connections shall be capable of withstanding all electrical,
mechanical and thermal stresses they may be subjected to, under normal or fault
conditions.
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Clearances between live parts and to ground shall be in accordance with the relevant
standards.

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

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

Each MV cubicle/panel shall be equipped with a suitable mimic diagram.

All panels/cubicles shall have approx. 10% spare room for mounting of future auxiliary
devices.

Water, steam or oil piping is not permitted in the cubicles.

Floor openings below cubicles shall be covered and sealed by the Contractor after
laying of cables, etc., so as to obtain fireproof and vermin-proof installations.

Where required gland plates with suitable glands shall be provided.

Phase rotation and color markings shall be employed throughout the Works.

6.5.2 Switchgear/Motor Control Center (MCC) Feeders and Starters


Circuit breakers, load break switches and motor starter units shall be of the removable
or fixed mounted type. Where two or more starters or feeders are contained in the same
cubicle, they are to be separated by barriers of sheet steel or fire proof insulating
material. If required, the metal surface of the cubicle shall be protected by fireproof
insulating material. The panels shall contain all respective starters and contactors with
their main incoming and outgoing power feeders.

The draw out switching devices shall be mounted on trucks or slide in chassis having
adequate guidance by greased sliding rails and/or rollers. They shall be connected to the
busbars by means of a self-aligning plug and socket arrangements. Drawing out the
switching device shall attain complete isolation of each circuit.

The main contacts shall have shutters, which automatically close upon withdrawal of
the switchgear. The withdrawal of large circuit breakers shall be facilitated by means of
cranks, gears or other facilities.

The contact surfaces of the plugs and sockets shall be silver-plated. The contacts shall
be amply sized and sufficiently strong to withstand maximum short circuit currents and
carry continuously the rated currents without damage or overheating of any kind.

The control circuits shall also be provided with plugs and sockets.

The removable units shall have clearly marked service, test and isolated (ready for
complete removal) positions. A mechanical interlock shall be provided to prevent
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withdrawal of the unit unless the main circuit has been opened. The unit shall positively
be locked in the test position before it is manually released for complete withdrawal.
The test position shall permit local and remote closing and tripping of the relevant
switchgear with the main contacts isolated from the power circuit.

Each switchgear room shall be furnished with a switching unit transportation carriage,
the height of which shall be adjustable to the different installation heights.

All circuit breakers, load break switches, starters and contactors shall be suitably rated
and controlled according to the electrical and mechanical performance and duties they
are assigned for. Automatically controlled feeders (motor feeders, outgoing feeders)
shall be equipped with a time delayed automatic tripping device operating in case of
voltage failure at the busbars or being actuated by another defined signal.

All motor starters, contactors and their associated devices shall be capable of operating
without overheating for a period of five minutes with a supply voltage of 70 % of the
nominal value. Means shall be provided to prevent pumping.

Motor feeders shall be equipped as follows:


• HRC fuses with auxiliary contacts and load break switch, or
• Fused load break switch, or
• Circuit breaker with instantaneous over current protection
• Starter combination
• Adjustable thermal overload and phase failure protection
• Automatic motors starters as required.

Molded case circuit breakers and miniature circuit breakers can be used if they are
properly selected to stand the maximum short-circuit current.

All starter and contactor units of the same rating shall be interchangeable. Remote
controlled motor starters rated 5 kW and above shall include provisions for remote
current indication.

Service hour meters shall be installed in the motor control centers if maintenance work
such as re-greasing, oil change etc. depend on the operation time of the motors.

6.5.2.1 Circuit Breakers


Circuit breakers shall be equipped with a driving mechanism composed of a spring
loaded, energy storing closing and tripping device. Remote controlled circuit breakers
shall be provided with an electric spring loading driving motor; manual spring loading
and control shall also be possible. Means shall be provided to prevent pumping while
the closing circuit remains energized should the breaker either fail to latch or be tripped
during closing due to the operation of a protective device.

Barriers of approved heat resisting, non-tracking insulating material shall separate the
CB phases.

The LV breakers shall be provided with main and isolating contacts, and with suitable
arcing contacts, magnetic arc quenching devices, arc chutes.
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The spring release of the closing mechanism shall be affected by means of a DC


solenoid coil and by means of a wing lever or mechanical push-in button. The closing
mechanism can alternatively be of the AC solenoid coil operated and latched type.

Tripping shall be effected by means of DC solenoid trip coil and by means of a


mechanical push-in button.

Large circuit breakers shall have a device to count the number of opening/closing
operations.

The molded case circuit breakers shall have trip coil. They shall have a thermal overload
of 125% of the normal full load current and instantaneous magnetic trips which operate
at currents exceeding 500% of normal full load currents or 600% of motor full load
current whichever is applicable.

Miniature circuit breakers shall be single-pole or triple-pole with adequate current


ratings. The operating as well as the overload mechanism shall be sealed.

The contacts of control relays and of higher rated circuit breakers and contactors shall
be silver-plated.

6.5.2.2 Contactors
LV contactors shall be of the air break type with arc shields, class AC 3 according to
IEC standards. All portions likely to suffer from arcing shall be easily removable.

When closed, the contactors shall withstand the system fault current determined by the
next coordinated short circuit tripping device. The associated thermal overcurrent
releases shall be adjustable in order to fit the motor requirements and be temperature
compensated up to 70°C ambient temperature.

6.5.2.3 Fuses
The HRC-fuses shall be suitably sized to cope with the connected loads at site
conditions.

They shall be of the current limiting type and be of such characteristic as to correspond
to the associated switchgear.

6.5.2.4 Load Break Switches


The load break switches shall permit manual operation from the front panel. Where
required they shall be designed to allow mounting of a remote control device.

They shall have a padlocking device and self-cleaning contacts with a high resisting
anti-arc case and with quick-making and quick-breaking action, capable to switch the
specified rated currents.

If suitable, the load break switches can be combined with the HRC-fuses.
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6.5.3 Switchgear/MCC Control


For local switchboard control, all circuit breakers and motor-starter-contactor units, if
applicable shall have:

• One (1) green-colored push-button for “OFF"

• One (1) red-colored push-button for “ON"

• One (1) position indicator of either the semaphore-type for circuit breaker,
electrically controlled, or indicating lamps, included above.

• One (1) amber-colored indicating lamp for fault indication of local protection
equipment (tripping of protection relay or device, blowing of power fuse, tripping of
miniature circuit breaker of control circuits). This lamp shall remain lit until
cancelled by resetting of the device having caused the fault indication. Facilities
shall be provided to repeat the alarms, individually or group-wise for remote
indication or recording.

Remote-controlled incoming and outgoing feeders as well as motor starters shall be


equipped with key-operated LOCAL - REMOTE selector switches.

The “OFF" control shall be effective at all locations independent of the selector switch
position while the “ON" control shall be restricted to the set selector switch position.

All manual operated Works shall have mechanical indications clearly indicating the
relevant position.

Each bus section of a distribution board shall have a blue-colored signaling lamp
indicating that the control supply is healthy, and each cubicle a yellow-colored signaling
lamp-indicating heater “ON".

Indicating lamps shall be of an approved low consumption type. The hoods covering the
lamps shall be made of transparent colored glass moulds or any other equivalent heat-
resistant and break-proof material and shall be either of the screw or any other approved
type to facilitate replacement of the lamps.

All indication lamp fittings of similar use shall be of the same size and type.

Where suitable, LED indicating devices are preferred to pilot lamps; they shall be of the
multi-element type.

Lamp test facilities shall be provided on each panel. Up to 3 panels, forming an


assembly can be fitted with one common lamp-testing device.

Individual panels or panel suites shall include indicating lamps for:


• Heaters on
• Control voltage
• Alarm/ trip

Generally the specified standard DC voltage(s) shall feed monitoring and protection
circuits as well as trips of circuit breakers. All other circuits may be controlled by AC.
Contactor-operating circuits shall be controlled by AC with the contactor solenoids
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preferably designed for DC, with pre-connected rectifier bridges. Where required,
latched contactors shall be provided. Aforesaid circuits shall be protected individually
by means of miniature circuit breakers with position monitoring. AC control circuits
shall be derived from the relevant busbar system via supervised main fuses, isolating
transformer and the above-mentioned individual MCB’s. Protection of trip circuits shall
be coordinated with the suppliers of the protection system.

Closing of the circuit breakers and contactors shall be possible in the voltage range
given in Chapter 6.3. Holding of contactors shall safely be affected at 70% of the rated
control voltage. Tripping devices shall operate at 50 - 120% of the rated control voltage
in case of mains dependent and at 75-115% in case of separate control voltages (DC
system).

If applicable, for local control of motors, valves, drives etc., the following push-button
shall be provided:

• One (1) Key operated selector switch having three positions; fixing the mode of
operation of the drive with regard to the following criteria;
• 1st Position: “Off" (there is no access to that drive neither by the incorporated
push button nor by the superposed control system).
• 2nd Position: “Local" means, the drive can be operated only by the incorporated
ON/OFF push button. (Mainly used for tests and or maintenance purposes).
• 3rd Position: “Remote" The drive is controlled by the proposed control system
only.

• One (1) “ON"- push button

• One (1) “OFF"- push button

• One (1) “Emergency OFF" - push button, which remains locked upon actuation and
which can be released only by means of a special key. The effectiveness of this
emergency push button shall not be restricted in any way. Its main function is the
protection of personnel and Plant under emergency conditions.

6.5.4 Small Wiring


All wiring within panels, racks, boards, etc. shall be of halogen free material insulated
stranded copper wires.

The insulation material shall be of halogen free material, tropical grade. The wiring
shall be capable of withstanding, without deterioration, the conditions prevailing at the
individual location of installation. The bare ends of stranded wires shall be provided
with squeezed sleeves or pins.

The minimum cross-section shall be as follows:


• 2.5 mm2 for all consumers (such as motors, heaters) and current transformer circuits
• 1.5 mm2 for control wiring above 60 V service voltage
• 0.5 mm2 for control wiring below 60 V and telephone wiring
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• About 0.2 mm2 in case the applied termination techniques of standard electronic
equipment do not permit the use of larger cross-sections.
• In case of grounding on control wiring below 60 V, 1.5 mm2 shall be used.

All secondary wiring shall be arranged and protected to prevent it from being damaged
by arcing or by mechanical effects.

Wiring shall be neatly run, bundled or in rigid halogen free material wire ways filled not
more than 70%.

Wiring shall terminate in one or more terminal blocks, arranged at the side or bottom of
each panel or compartment. Internal wiring between instruments or other devices not
using the terminal block shall be permitted within the same compartment only.

Terminal blocks shall be numbered consecutively and shall consist of single insertion
type terminals, non-inflammable synthetic material lined-up in one row. All terminals
shall have two (2) separate pressure-clamping plates suitable for connection of
incoming or outgoing, stranded and solid conductors, respectively. Terminals with
clamping screws in direct contact with the conductor are not acceptable.

The following categories of terminals shall be provided and arranged as follows:

A. terminals for power circuits

B. terminals with short-circuit facilities for current transformer circuits

C. terminals for measuring, signal and control circuits, where required, with bridging
facilities to the neighboring terminal

All category C terminal blocks shall contain 20% spare terminals. Insulating barriers
shall be provided between each pair of power circuits and between the terminal
categories. The height and the spacing shall be such as to give adequate protection to the
terminals whilst allowing easy access to the same.

6.5.5 Marking of Equipment and Wiring


All internal equipment and wiring shall be neatly and clearly marked as indicated on the
schematic and wiring diagrams. Internal wiring and cables shall be marked with sleeve
type engraved marking. Marking system and marking material shall be subject to
approval by Employer. Identification of the respective conductors shall be in accordance
with the requirements of ICEA/NEMA

6.5.6 Color Coding of Electrical Connections


Live parts of electrical connections as well as cable conductors shall be color coded as
follows
System / Part of Plant Phase Color of Additional Remarks
Designation Conductor Conductor
Identification ¹)
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System / Part of Plant Phase Color of Additional Remarks


Designation Conductor Conductor
Identification ¹)
Medium and High Voltage *) Depends on the
AC-Network: insulation of the
cables respectively
busbar
- Phase R L1 arbitrary *) 1)
- Phase S L2 arbitrary *) 1)
- Phase T L3 arbitrary *) 1)
- Protective grounded PEN green-yellow
neutral

Low Voltage AC-Network:


- Phase R L1 brown
- Phase S L2 black
- Phase T L3 grey
- Neutral N blue
- Protective grounded PEN green-yellow
neutral

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

- switched plus arbitrary

Current Transformer L1, L2, L3 black Imprinted numbers


Circuits (K/L):

Voltage Transformer
Circuits:
- Phase R, S, T, L1, L2, L3 black Imprinted numbers
Protective grounded
Protective grounded neutral
- Grounded N black Imprinted numbers
neutral

Control and Measurement black Imprinted numbers


Circuits, Auxiliary Circuits

1) The additional conductor identification shall be made by the use of cable shoes with colored collar of insulation
material, identification collars, colored special tapes, etc.
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6.6 Instrument Transformers


Current and voltage transformers are to be housed and designed to suit their particular
duties. They shall meet the requirements of the latest relevant approved standards for
metering and for protection and be capable of withstanding without any damage or
deterioration:
• The continuous thermal current rating of the associated switchgear and
• The maximum short-circuit level of the circuit for a period of one (1) second.

All current transformers shall be capable of carrying rated primary current with an open-
circuited secondary winding for one (1) minute without damage or deterioration.

Separate cores shall be provided for protection and metering circuits. The current and
voltage transformers shall have adequate accuracy, saturation factor and rated burden.
The Contractor shall determine the burdens and accuracy class of the secondary
windings taking into consideration the most unfavorable conditions.

If no reference is made in the Particular Technical Specifications the secondary


windings of instrument transformers shall have the following ratings:
• 1 A for current transformers
• 100 V for voltage transformers

The secondary windings shall be wired to suitable terminal boards and grounded at one
point in the circuit.

The terminals of current transformers shall be provided with short-circuiter.

Switching of current transformer circuits is not permitted.

Voltage transformers shall be fused in both phases on the secondary side by means of
miniature circuit breakers as close as practicable to the transformer terminals. The
miniature circuit breakers shall be equipped with auxiliary contacts used for alarms,
tripping and interlocking as required in the application.

All current and voltage transformers shall be provided with a plant label giving type,
ratio, class, output, serial number and connections.

The Contractor shall supply manufacturer’s test certificates on tests and measurements
to be performed in accordance with applicable standards. The current transformers and
their associated circuits shall be tested at site by the primary injection method.

6.7 Protection Devices


The main parts of the plant shall be protected and interlocked so as to prevent false-
operations, other fault occurrences and to maintain safety during all operation phases.

Electric protection relays or protection systems shall be the standard product of an


experienced protection relay manufacturer. They shall be of the static analogue or
numerical type, suitable for tropical conditions and be mounted in suitable dust proof
and shock-absorbing casings or panels. They shall not be affected by external magnetic
fields or any other influence (radio, computer, signals, impulses, etc.).
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The protection relays or protection systems shall be equipped with all necessary
auxiliaries such as tripping unit, time relay, external resetting device. The relays shall
provide easy access for testing and setting purposes.

Pre-warning alarms shall be initiated as early as possible before the protection system
trips, in order to enable the operators to take precautions. Tripping of a protection
system as well as the sources of the protective action shall be indicated and recorded as
an alarm.

Unless otherwise required for special purposes, protection relays shall remain in the
tripped position until the operator resets the relay manually. The protection and
auxiliary relays shall be grouped and mounted on plug-in modules or stationary-
mounted on swing frame with separate plugs and sockets to feature easy replacement
and testing. The construction shall be sturdy and such that all parts are easily accessible
for adjustment. No protection relay shall be installed in MV cubicles except where
approved. In this event they shall be arranged in compartments separated from the
switchgear.

All relays shall have sufficient contacts and/or auxiliary relay contacts to perform all the
tripping, inter-tripping, interlocking, indication and alarm functions required. Spare
contacts (1 NO/1 NC.) shall be provided for later use. The relay contact rating shall be
for the specified standard voltage and for 200% of the nominal passing current.

Testing of the individual relays shall either be effected by stationary-mounted or


portable testing devices.

6.8 Auxiliary Equipment

6.8.1 Auxiliary Switches


Where appropriate, each item of the plant shall be equipped with all necessary auxiliary
switches, contactors and devices for indication, protection, metering, control,
interlocking, supervision and other services. All auxiliary switches shall be wired up to
terminal blocks on the fixed portion of the plant.

All auxiliary switches and mechanisms shall be mounted in approved accessible


positions clear of the operating mechanism and are to be protected in an approved
manner.

6.8.2 Control Switches


Where applicable, control switches for electrically operated circuit breakers shall be of
the discrepancy type. They shall operate clockwise when closing the circuit breakers
and anti-clockwise when opening them. The control switches shall be so designed as to
prevent them from being operated inadvertently, and where switches of the discrepancy
type are used they shall require two independent movements to effect operation.

Switches for other apparatus shall be operated by shrouded push buttons or have
handles of the spade type.
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Control, reversing, selector and test switches shall be so mounted, constructed and
wired as to facilitate the maintenance of contacts without the necessity for disconnecting
wiring.

6.8.3 Anti-Condensation Heaters


Each individual enclosure accommodating electrical Works which is liable to suffer
from internal condensation due to atmospheric or load variations shall be fitted with
heating devices suitable for electrical operation at the specified standard AC voltage,
being of sufficient capacity to raise the internal temperature by about 5°C above the
ambient temperature. Heaters in motors and similar equipment shall be switched on
automatically upon opening of the motor starter and vice-versa. Heaters in switchgear
and / or MCC cubicles, control cubicles, panels, etc., shall be controlled automatically
by adjustable hygrostats (setting range about 50 - 100% relative humidity). The
electrical apparatus so protected shall be of such design that the maximum permitted
temperature is not exceeded if the heaters are energized while the apparatus is in
operation.

Heaters shall be equipped with a suitable terminal box. All equipment, whether fitted
with a heating device or not, shall be provided with suitable drainage and be free from
pockets in which moisture can collect.

6.8.4 Electrical Connections


Bolted connections shall correspond to the applicable DIN Standards and have two
washers and one spring washer. Bolt terminals of machines (motors, transformers, etc.)
shall be equipped with secured nuts, two washers and spring washer, all the above
elements being of corrosion-proof material or plated accordingly.

Tightening of such bolt connections shall be done with a torque wrench set to values to
be given by the Contractor before commencement of erection work.

Busbar interconnection of individual units (switchgear/busducts/ transformers) shall be


done by flexible joints. They shall be rated as per the respective busbars; the length shall
ensure the flexibility against vibrations, thermal or operational displacements and also
withstand the dynamic short circuit stresses.

6.9 Cables and Cable Laying

6.9.1 General
The Contractor shall provide the relevant design and engineering of the relevant cable
systems and in close co-operation with other concerned contractors, prepare the cable
installation drawings with cable routing, connection diagrams, and cable lists, details,
etc.

The Contractor shall select the most suitable cable routes and raceways ensuring a
minimum of interference with other installations and other Lots.

The maximum continuous current carrying capacity of each individual cable type and
cross-section used shall be determined, taking into account site conditions. The resulting
load reduction factors are subject to approval.
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All cables shall be designed to cope with the short circuit conditions and the applied
protective system.

Cable conductors shall be of annealed, high conductivity copper conductors lay up and
rendered smooth and free from defects likely to injure the insulation. Under no
circumstances cable through joints / mid joints will be accepted.

Cables running on or nearby hot surfaces shall be of the copper sheathed mineral
insulated (MICC), silicon-rubber insulated, or other approved type.

All cables either running outside of buildings or directly laid in the ground, the whole or
part of their length, shall be of the highest thermal and mechanical strength. They shall
be single wire or tape armored.

All armored cables shall have an outer sheeting to prevent the armoring from corrosion.
The armoring is also intended to avoid damages caused by rodents.

The identity of the manufacturer shall be provided throughout the length of the cable by
embossing the outer sheath with “name of Manufacturer - year of manufacture“. The
letters and numerals shall be raised and shall consist of upright block characters. The
gap between the identification marks shall not be greater than 200 mm.

6.9.2 Standards
Unless otherwise stated hereafter, ratings, characteristics, tests and test procedures etc.
concerning the materials described in this section shall comply with the provisions and
requirements of the IEC Publications each as they apply.

In order to minimize the required number of type of cables, all cables shall be standard-
ized regarding their cross sectional area, number of strands and marking of strands.

6.9.3 Insulation Materials


For insulation and sheathing only halogen free material according IEC 60754 shall be
used.

All cables shall be at least flame retardant according to IEC Publication 60332.

6.9.4 Rated Voltages and Test Voltages


The rated voltage of the AC and DC power cables shall be 1/0.6 kV. The test voltages
shall be as follows:
− Power frequency withstand voltage (factory test) 3.5 kV
− Power frequency withstand voltage (site test) 2.0 kV

The rated voltage of the control, measuring and signal cables shall be 500/300 V. The
test voltages shall be as follows:
− Power frequency withstand voltage (factory test) 2.0 kV
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6.9.5 Voltage Drops


All power cables shall be dimensioned to stay below a 3 % voltage drop at nominal
operating current. The voltage drop of all controlling, measuring and special cables shall
be determined in each individual case, in order to assure correct service of all connected
apparatus and instruments even under the most severe variations of the power sources.

6.9.6 Power Cables


All cables shall be selected to withstand without damage the short-circuit current in
conductors and armor. The minimum cross-section of the conductors, with due regard to
a maximum allowable voltage drop shall be at least:
• 1.5 mm² for secondary power cables
• 2.5 mm² for main power cables (such as motors, sockets, heaters) and instrument
voltage transformers
• 4 mm² for instrument current transformers

For cross-sections equal or larger than 120 mm2, single core cable shall be used.

The cross sectional area of the neutral and protective ground conductor in percentage of
the phase conductor shall be as follows:

Phase conductor Neutral conductor PE conductor


1.5 – 16 mm2 100 % 100 %
> 16 mm2 50 % 50 %

Low voltage power cables shall be of the extruded solid dielectric insulated type.

Medium and high voltage power cables up to 275 kV shall be of the cross-linked
polyethylene insulated type.

The XLPE cables shall be capable of continuous operation at a highest system voltage
as specified with a maximum conductor temperature of 90°C, and a maximum
temperature under fault conditions of 250°C.

All conductors shall have colored insulation according to the phase colors or,
alternatively colored plastic sleeves can be used at all cable terminations.

6.9.7 Instrumentation, Control and Communication Cables


The control cables shall be of the stranded, multicore type.

Cables for analogue signals shall have a common screen of metal tape, cores shall be
twisted pairs and concentric circular stranded (7 strands) conductor.

Communication cable shall have outer common screen of metal type, cores shall be
twisted pairs individually screened.

The cross-sections shall be adequate for the design of the plant. In all cases, the
maximum voltage drop on the cables shall not exceed 5% at the worst load and
temperature conditions.
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The minimum cross-section of each core of the instrumentation, control and


communication cables shall be as given below:
• 1.5 mm2 for all cables above 60 V service voltages
• 1.5 mm2 for all cables leading from the terminal boxes to individual local
instruments
• 1.5 mm2 for all thermocouple compensation leads
• 0.5 mm2 for all multicore cables leading from local terminal boxes to the control
room (if applicable).

Multicore cables with more than 7 cores shall have approx. 20% spare cores for future
use.

Multicore cables shall be number-coded and/or color-coded or identified by other


suitable means.

The color-coding or other identification system shall be shown on the circuit/connection


diagrams.

6.9.8 Cable Laying

6.9.8.1 General
All cables shall in principle be laid in one single length. If it is not practicable to lay the
cables in one length, approved connections shall be used.

As appropriate for the various locations the cables shall be installed in cable ducts,
raceways, conduits, tray systems, cable trenches or directly laid in the ground.

Cables running inside buildings or concrete trenches shall be laid on trays to be supplied
by the Contractor who supplies the cables except where specified.

The trays shall be of adequate strength and size to carry the specified number of cables,
providing approx. 25% spare capacity. The design of such trays shall include a safety
factor to avoid permanent distortion when supporting erection staff during cable
installation. The trays shall be of suitable aluminum alloys or hot-dip galvanized steel
standard materials.

In chemically endangered areas all trays, supports, ladders, etc., shall be of hot-dip
galvanized steel elements painted with suitable epoxy-resin paint or provided with a
sintered coat of suitable material for protection against such chemical environment.
Cable trays shall normally be of the ladder type consisting of bars with rungs, evenly
spaced (max. 500 mm) according to requirements. Perforated, covered metal trays shall
be used in highly polluted or otherwise endangered surroundings. All trays hall be
rigidly fixed on supporting steel structures, masonry or galvanized racks. Cable trays
arranged one above the other shall be at least 300 mm apart in case of power cables and
200 mm in case of control cables.

Cables laid on trays or racks shall be properly fixed or clamped. Supports and racks
shall be arranged to facilitate removal or replacement of cables.
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Cables branched from general raceways and directed to the relevant equipment shall be
suitably protected over their entire length by e.g. galvanized steel conduits sealed at
their ends against ingress of water. Generally in industrial areas and machine rooms, the
conduits shall be fixed on steel structures or on walls as required. In general control
rooms and offices, for architectural reasons, the conduits shall be embedded or the
cables shall be laid in approved surface mounted trunks.

Conduits embedded in concrete or block work shall be of suitable PVC-type. Cables lay
outdoors, across roads in concrete or foundations shall run in hard PVC plastic pipes
buried in the ground in a depth not less than 600 mm or embedded in concrete
foundations at suitable depth.

The cross-section area of conduits shall be utilized to 60% only. Conduits shall
terminate in concrete manholes before entering buildings. Manholes and pull-pits shall
be provided where required to facilitate cable installation.

Cables on brick walls or similar civil structures can be laid in conduits (painted
galvanized steel conduits within the reach of persons or erection/maintenance devices)
or in prefabricated installation channels made of galvanized sheet metal or plastic.

Unarmed cables shall be properly protected against mechanical damage when leaving
ducts or covered trench works and the like.

Cables directly buried in the ground shall be laid as follows:


• Cable trenches shall be excavated approx. 110 cm deep; the width shall be
appropriate to the quantity of cables.
• Bottom of trenches shall be covered by a 10 cm layer of fine, clean material
(preferably sand)
• Cables shall be laid on this layer of fine material
• Cables shall be covered by a 15 cm layer of fine, clean material (preferably sand)
• Cable protection tiles shall be laid along the cables
• Trench shall be carefully backfilled with excavation material approx. 20 cm high; the
material shall be adequately compacted
• Colored plastic warning tape(s) shall be laid on top of this layer
• Trench shall be completely backfilled, material compacted and surface reinstated.
Excess material shall be removed.

Except where specified, civil works for excavation and backfilling, are not included this
Contract. However the Contractor shall supervise this particular grounding works and
report to the Employer.

The Contractor shall provide in due course all required information on cable ducts,
trenches, manholes, block-outs, foundations, etc. which shall be constructed by the civil
contractor.

Minor civil works like slotting or chiseling shall be included in this Contract. A distance
of approx. 30 cm shall be kept to other services.
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The Contractor shall be responsible for any damage caused by him to the buildings, and
shall be responsible also for making good finishing of all buildings affected by his
works.

The Contractor shall observe the following particulars for cable installation in concrete
trenches:
• Cable trench covers shall be removed in sections, according to the progress of work.
• Removed covers shall be stored in such a way that they do not create a hazard to
people or traffic at site.
• Cables laying in open trenches for more than two weeks shall be protected against
sun radiation.
• Open trenches shall be properly secured by red warning tapes both sides along the
trench.
• The Contractor shall replace any cover, cable or cable tray having been damaged
during installation.
• Cable trenches shall be cleaned from dirt, sand, etc., before closing.
• Trenches shall be closed as soon as possible.

All works specified above shall be carried out by the Contractor.

6.9.8.2 Partition and Sealing


Fire-partitions shall be provided when cables are passing through different fire zones or
when entering cubicles and panels.

Cable passages into buildings shall be sealed fire-and waterproof.

Accessible cable galleries shall have fire-barriers at suitable spacing including normally
open fire doors, which are closed automatically in case of fire.

6.9.8.3 Cable Arrangement


Power and instrumentation / control cables must be run on separate cable trays, where
this is not possible they must be separated by a minimum of 300 mm, subject to
approval. Medium and high voltage cables of different systems shall be segregated in
order to minimize mutual effects of short circuits.

Cable crossing in the same plane shall be avoided.

Special precaution shall be taken to ensure that no magnetic circuit is formed around
single core cables laid in single or trefoil formation, or around any cable liable to carry
unbalanced currents.

The pulling, and fixing and terminating of cables shall be strictly in accordance with the
manufacturer’s instructions, using the recommended tools and appliances.
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6.9.9 Cable Termination


For all terminations of wires and cables, the insulation shall be neatly stripped without
nicking the strands of the conductors.

Cable lugs for power cables shall be of adequate size. Cable glands or clamps shall be
fitted in all cases to prevent stresses on conductors or terminals. Fork type cable
terminal ends will not be accepted.

The sealing compound and sleeves used in terminations has to suit the conditions under
which the cable is to operate. MV and HV cable terminations will only be accepted if
the insulation readings, 24 hours after making off, is higher than 100 MΩ.

Some slack cable in a loop or other suitable form is to be allowed at a convenient place
in the runs where required.

6.9.10 Tests

6.9.10.1 Workshop tests


All cables shall be tested in accordance with the Contractor’s detailed quality assurance
program. The extent of thee factory test and the test methods shall be governed by the
recommendations of the relevant IEC publications.

6.9.10.2 Site tests


Power cables shall be tested as follows:
• Cable checking
• Continuity checking
• Insulation resistance measurement in accordance with the applicable codes and
standards
• Measurement of voltage drop of critical lengths
• Dielectric test according to IEC 60502 (MW and HV cable only)

Control, instrumentation and communication cables shall be tested as follows:


• Cable checking
• Continuity checking
• Insulation resistance measurement in accordance with the applicable codes and
standards
• Measurement of voltage drop of critical lengths

Fiber optic cables shall be tested as follows:


• Operational tests to verify correct operation of the optic system
• Connector attenuation tests to measure losses in all connectors in dB
• Transmission attenuation test to measure transmission losses in dB/km
• Reflection tests to find position and type of fault (crack or break) of the fiber
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• Speed tests to measure one-way propagation time.

6.10 Equipment Grounding


The contractor shall design and install a grounding system for protection of persons and
material to allow safe service and maintenance work on the installations.

The grounding system shall be designed to avoid dangerous touch or step voltage. The
grounding conductors shall be dimensioned to carry without any damage the maximum
ground current expected under fault conditions.

The dimensioning shall be coordinated with the protection devices of the various
components of the plant. The conductors shall be bare E-copper that shall reliably be
protected against mechanical damages and corrosion. Provisions shall be made to ensure
a constant low ground resistance.

Each conductor shall have its own separate connection point. Pressed on closed shoes
shall be used for connections to bars.

The Contractor shall connect all equipment included in the scope of supply of his
Contract to the general grounding system of the plant. In addition to the grounding of
cable screens, all equipment such as cubicles, motors, etc. shall be connected directly to
the grounding system using copper wire. All metal parts such as steel liners, penstocks,
supports, covers, railing, etc. shall be connected to the grounding system.

Shielding of control, instrumentation and communication cables are to be grounded at


the cubicle end of the cable and not at the field device side.

6.11 Explosion-Proof Works

6.11.1 General
According to the kind of oils and fuels used, explosions in hazardous locations may be
caused by standard type electrical Works. Therefore, the installations in such locations
shall generally be kept to a minimum with said Works designed or installed in
compliance with the latest issue of IEC Recommendation 60079 and the appropriate
articles of the American National Electrical Code (NEC) or the German VDE Standards
0165, 0170 and 0171.

6.11.2 Definition of Hazardous Locations


Hazardous locations shall be defined as follows:

A) locations are those:


(1) where hazardous concentrations of inflammable vapors or gases exist
continuously, intermittently, periodically under normal conditions of operation
and maintenance and with normal leakage, and
(2) where the breakdown or faulty operation of process equipment could release
explosive concentrations of fuel and cause a simultaneous failure of electrical
Works.
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B) are those:
(1) adjacent to locations indicated in paragraph A) which may occasionally be
reached by hazardous concentrations, and
(2) where inflammable volatile liquids or gases are handled, processed, or used, but
where concentrations are not normally hazardous because liquids or gases are
handled in closed systems, and
(3) where hazardous concentration is normally prevented by positive ventilation.
These locations become only hazardous when the ventilation systems fail.

6.11.3 Design Features


The design features of electrical Works and/or circuits to reach explosion proof
conditions shall be selected with due regard to the place of installation and the kind of
Works.

The main features shall be as follows:


• Pressure and Flame-proof Enclosure
• All parts which may ignite a hazardous atmosphere shall have an enclosure of
sufficient strength to withstand the maximum pressure caused by ignition of the
most inflammable mixture of the gas involved. All necessary joints of such
enclosure shall be provided with long fits (minimum 25 mm) and close clearances
(equal or smaller 0.6 mm) to cool the escaping flame and to prevent flame
propagation to the outside atmosphere.
• Oil Immersion:
• The parts capable of igniting inflammable or explosive mixture shall be immersed in
oil to such an extent as to prevent ignition of explosive mixtures above the surface
of oil by means of sparks or hot gases produced under oil.
• Increased Safety:
• To obtain an increased degree of safety on electrical Works, special measures shall
be taken to prevent non-permissible high temperatures, sparks or arcs inside and
outside of the Works on which they do not occur under normal working operations.
• Intrinsic Safety:
• An electrical circuit or part of such a circuit shall be considered as intrinsically safe
if neither during normal working operation nor under fault conditions explosive
mixtures are ignited by means of arcs, sparks, or any heat generation.
• Any other approved feature not mentioned above.

All explosion-proof Works shall be of approved design and must have undergone type
tests according to the appropriate standards.

The selection of such Works with reference to design features and allocation to
hazardous groups shall be subject to approval by the Employer.
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7 INSTRUMENTATION AND CONTROL EQUIPMENT (I&C)

7.1 Operation Levels

7.1.1 General
The following operation levels shall be implemented:

• Operation Level 0: local distributed

• Operation Level 1: local centralized

• Operation Level 2: Plant

• Operation Level 3: Remote

At each operation level a local / remote selector switch shall be installed for the
selection between the respective local operation level and the next higher level of the
operation level hierarchy.

7.1.2 Operation Level 0


Operation Level 0 shall be the local distributed operation of each device of the plant.
This operation level shall be operable independently of the control system. It shall be
implemented with switches, pushbuttons or similar conventional electrical or
mechanical devices.

Care shall be taken, that each and every component can be operated conventionally in
case of an outage of the control system, especially also the synchronization, the
generator brake, emergency shut off valve etc.

Only a limited basic interlocking implemented hardwired electrical or mechanical shall


be foreseen on this operation level.

Operation level 0 is intended to be used only for test purposes and in emergency
situations. It can be assumed that skilled operators only will make operations in this
operation level.

The electrical protection of generators, main transformer, lines, bus bars etc. shall be
active also in Operation Level 0. All trip signals must be hardwired to the respective trip
coils.

The mechanical protection of turbine, generator and main transformers shall be


implemented in such a way, that it is also active with the programmable controller
controlling the respective device is out of service. The mechanical protection can be
implemented either conventional, in a protection relay or in an independent
programmable controller. If the mechanical protection is implemented in a
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programmable controller, this controller must be supervised by another controller


operating independently from the first one.

All emergency pushbuttons shall be independent from the control system.

In case of a generating unit, the emergency shutdown sequence to standstill including


application of the generator brakes on reaching the defined speed and, if applicable,
closing of hydraulic shut-off devices shall be active independent from the control
system,

7.1.3 Operation Level 1


Operation level 1 shall be implemented in the control system. A touch panel or similr
device shall be the man.-machine interface. Each man-machine interface shall be
connected to one of the programmable controllers and shall be mounted in the same
panel as the respective controller.

Each device shall be operable from one of the man-machine interfaces. The interlocking
shall be programmed in the programmable controller.

The communication between man-machine interface and the respective programmable


controller shall work independent from the plant process network. Operation Level 1
shall be operable even in case of a breakdown of the plant process network.

7.1.4 Operation Level 2


Operation level 2 is the plant control level. The main components of the plant control
level are the plant computers located in the control room, theit peripheric devices like
printers, large screens etc and the plant control network connecting the plant computers
with the programmable controllers distributed over the plant.

The plant computers shall be redundant making sure that one computer is operable also
in case of a failure of the second one.

The plant network shall be structured in such a way that an interruption of the network
cable connection on one place shall not affect the communication between the plant
computers and the controllers.

A failure of one device connected to the network shall not have influence on the
communication between the others.

For the network connections between the control room and the field fiber optic cables
shall be used. The fiber optic cables shall have be mechanical protected and rodent
resistant.

7.1.5 Operation Level 3


Operation Level 3 is the remote operation of the plant.
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7.2 Operation Modes

7.2.1 General
The following operation modes shall be implemented in case of the unit control:

• Manual

• Step by Step

• Automatic

7.2.2 Manual
Manual operation is the manual operation of a single field device using the appropriate
conventional actuator or man-machine interface.

Manual operation mode shall be implemented at Operation Level 0 (by conventional


means independent from the control system) and Operation Level 1 (within the control
system).

For important devices which are not part of an automatic sequence (for instance circuit
breakers, disconnecting switches and grounding switches of a high voltage switchyard,
manual operation has also to be implemented at Operation Level 2 and if specified in
the PTS at Operation Level 3.

7.2.3 Step by Step


Step by Step operation mode is the operation of a predefined sequence between two
operation states step by step. The operator has to release manually the next step after
completion of the previous.

Step by Step operation mode shall be implemented at Operation level 1 and if specified
in the PTS at Operation Level 2.

7.2.4 Automatic
In automatic operation mode, the transition between predefined operation states (like
from unit standstill to unit load operation in case of a generating unit or a feeder
changeover in case of a low voltage distribution) is possible using preprogrammed
sequences. The operator has to select the desired state and to activate the sequence
which will then be performed automatically. Each step has to be supervised for timely
completion. In case of a timeout, the sequence has to be cancelled and appropriate
action has to be taken to bring the concerned part of the plant to a safe state.

Automatic operation mode has to be implemented at Operation Level 1 and Operation


Level 2. The grade of implementation for Operation Level 3 has to be defined in the
PTS.
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7.3 Design Criteria

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

The Works shall be pre-assembled to the highest extent in the Contractor's or Sub-
Contractor's workshop, e.g., shop welding of thermometer wells and other connections,
wiring of boards, desks, etc., including internal wiring and installation of devices shall
be carried out. Fragile instruments shall be removed for transportation to site.

All components shall be suitable for continuous operation under site conditions.
Materials for instrumentation and control equipment, including piping material which is
exposed to the measured media, shall be selected accordingly.

All components shall be compatible with other electrical, electronic and mechanical
Works.

7.3.2 Sizes of Indicators, Recorders, etc.


The meters, instruments and recorders shall be of standard size, to be selected to
guarantee unique appearance of switchgears, control panels, control desks, etc. The
front glasses shall be of the anti-glare type. The scales may be 90° type for local control
panels but must be 270° type for control room instrumentation.

The indicating instruments and recorders shall have the following or similar sizes:

Indicators on local control panels, 72 x 72 mm or


LV, MV and HV switchgears 96 x 96 mm

Indicators on vertical sections of control 96 x 96 mm


desks in control room and on rectifier or
converter panels

Indicators on horizontal parts of control desks 48 x 48 mm


in control room

Indicators on control panels in control room 96 x 96


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When incorporated in mimic diagrams

Recorders 144 x 144 mm


(for line and 6-point recorders)

Pressure gauges and other dial type preferably 150 mm diameter


instruments (local)

The control switches, adjusters, etc., on the panels and desks shall harmonize with the
utilized indicator sizes.

7.3.3 Transmitter Racks and Piping


Wherever practicable, transmitters for flow, pressure, etc., shall be installed in readily
accessible positions in the proximity of the measuring point, free from vibration and
protected against damage, moisture, dust, corrosive air, and great temperature changes.

The transmitters shall be grouped and assembled as far as practicable on local


transmitter racks or in cubicles with glass or Plexiglas-front.

The connecting lines between the primary elements and the transmitters shall be
installed inclined in order to ensure that no air pockets or water locks are created.

7.3.4 Special Local Conditions


If the prevailing local conditions require special measures, the following shall be
observed for the I&C equipment:

• All local indicators shall be of stainless steel

• All copper pipes shall be protected with an external plastic sheath

• All external bolts and screws shall be of non-corrosive material

• All secondary shut-off valves, balancing and drain/blow-off valves shall be of the
non-corrosive type

• All metallic instrument piping shall be protected with corrosion protecting painting,
or shall be of non-corrosive materials

• All I&C equipment exposed to sun shall be protected against direct sun radiation.
This can be done by protection casings, sun shields, etc.

7.4 Measuring Systems

7.4.1 General
The components shall quickly respond to any changes of the measured magnitudes.
Measuring ranges of indicators, transducers, etc., shall be selected in such a way that the
rated value of the measured magnitude covers approx. 75 % of the range.
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All local instruments shall, as far as practicable, be mounted vibration free to allow
good reading. Wherever required, damping elements shall be used.

Related systems shall be grouped together in local panels.

All local indicating instruments and test connections shall be included in the respective
Works as integrated parts. The scope of local indicating instruments and test
connections shall enable the operator to properly survey the Works, and shall also allow
to adequately carrying out all acceptance and other tests.

7.4.2 Flow Measurements


The primary elements of flow meters shall be standard Venturi tubes, pilot tubes,
standard orifices, inductive or ultrasonic type. Their design and performance shall be in
accordance with applicable standards.

The design and arrangement of tapping points, piping and valves shall be in accordance
with VDI/VDE rules 3512.

Arrangement: The arrangement of the throttling devices, the straight lengths upstream
and downstream from the throttling device shall be in accordance with the said
standards. Bends shall be at a sufficient distance upstream from the throttling device,
particularly when large orifice ratios are used.

7.4.3 Temperature Measurements


Resistance thermometers and thermocouples shall be equipped with water-proof
connection heads. Thermometer arrangements shall be such that the connection heads
do not become warmer than 80°C, and the measuring inserts are easily exchangeable.

The temperature sensors shall be selected in such a way to minimize the number of
different spare inserts.

Resistance thermometers shall be used as far as possible. They shall be of type PT 100,
four-wire system, coping with DIN 43760.

The use of dial-type contact thermometers shall be restricted to bearing metal and oil
temperature measuring. In all other cases, thermocouples or resistance thermometers
and electric contact modules (monitors) shall be used. Glass thermometers or similar
will not be accepted as contact thermometers.

7.4.4 Pressure Measurements


Pressure gauges shall be shock and vibration-proof (preferably by filling with glycerin)
and shall be equipped with toothed wheels and toothed segments of the machined type.
They shall completely be made of stainless steel.

Higher than rated pressure shall not deteriorate the pressure gauge or affect its
calibration. The pressure gauges shall be equipped with a radial connecting stud, to
allow the mounting on a gauge holder.

Pressure gauges with potentiometers will not be accepted for use as a pressure
transmitter.
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Pressure gauges and transmitters for inflammable liquids shall have filled systems and
the filling liquid shall be separated from the inflammable liquid by means of adequate
isolating membranes.

Each gauge, pressure switch and transmitter for absolute or differential pressure shall be
equipped with a pressure gauge isolating valve including a test connection of the
screwed type M20 x 1.5 mm so that such device can be removed without any
disturbance of the plant operation.

Pressure gauges and transmitters for pressures of 10 bar and above, shall not be directly
mounted on the pressure tapping point. They shall be mounted apart from the tapping
point on gauge holders or gauge boards. Whenever possible, pressure gauges and
transmitters shall be groupwise combined on racks or consoles.

Pressure gauges for high pressures shall be equipped with a relieve valve for safety
reasons in case of leaks (with a rubber reverse flow check).

In case of flowing substances, the measuring point shall be selected in locations of


undisturbed flow.

If the pressure is pulsating, the devices concerned shall be connected via flexible tubes
or other pulse-absorbing means.

In general, all pressure gauges, transmitters and pressure contacts shall easily be
accessible for maintenance and supervision.

The design and arrangement of tapping points, piping and valves shall be in accordance
with VDI/VDE rules 3512.

The scales shall have a diameter of 150 mm with black letters and figures on a white
ground. The calibration shall be in accordance with chapter units.

The adjustment of the pointer shall be possible by means of an adjustment device


without removing the pointer from its axle.

The high and low pressure connections of differential pressure gauges shall be marked
accordingly.

All casings shall be dust and watertight and be made of stainless steel.

7.4.5 Level Measurements


The liquid level measurements in reservoirs and tanks with atmospheric pressure shall
be made by means of pressure transmitter of mercury-free type, by displacement-type
transmitters or float-disc-transmitters. Level switches shall be of the externally mounted
float or displacement operated type. The switch shall not have any packing gland and
there shall be a minimum of moving parts.

7.4.6 Electrical Measurements


Electrical instrument transformers are specified in Chapter 6.6 of this General Technical
Specifications.
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Electrical measurement converter shall be of the 4-20 mA or ± 10 V type.

All Electrical instruments shall be of flush mounted design, dust and moisture-proof and
fitted with non-reflecting glass. They shall comply in any respect with the requirements
of IEC Publication 60051.

Except for instruments employed for Works performance tests all instruments shall have
an accuracy class of 1.5.

AC ammeters and voltmeters shall have moving iron system for connection to the
secondary side of instrument transformers. DC measuring instruments shall have
moving coil systems of the same accuracy. Wattmeters shall have electro-dynamic
measuring mechanisms or alternatively a moving coil mechanism if fed by transmitters.
Wattmeters shall be suitable for unbalanced systems.

All indicating instruments shall generally withstand without damage a continuous


overload of 20% referred to the rated output value of the corresponding instrument
transformers. Ammeters shall not be damaged by fault-currents within the rating and
fault duration time of the associated switchgear via the primaries of their corresponding
instrument transformers.

All instruments and apparatus shall be capable of carrying their full load currents
without undue heating. All instruments and apparatus shall be rear connected, and the
enclosures shall be grounded. Means shall be provided for zero adjustment of
instruments without dismantling.

All voltage circuits to instruments shall be protected by MCB's in both phases of the
circuit, installed as close as practicable to the main connection. All power factor
indicators shall have the star point of their current coils brought out to a separate
terminal which shall be connected to the star point of the current transformer secondary
windings.

When more than one measured value is indicated on the same instrument, a measuring
point selector switch shall be provided next to the instrument and shall be engraved with
a legend specifying each selected measuring point.

Current transformer connected Ammeters provided for indication of motor currents


shall be provided with suppressed overload scales of 2 times full scale. The dials of such
ammeters shall include a red mark to indicate the full load current of the motor.

Instrument scales shall be submitted for approval by the Employer. All instruments
mounted on the same panel shall be of same style and appearance.

All metering circuits shall be terminated in marked terminal blocks for remote metering
purposes.

7.4.7 Position Measurements


Position transmitters of the potentiometer type will not be accepted. Inductive or
capacitive type shall be provided.

Position transmitters for continuous position indication and measuring transducers shall
be of the 2-wire type and shall have an output current of 4-20 mA (± 10 V resp.).
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7.4.8 Limit Switches


Limit switches shall be provided for all electrically operated devices such us gates,
valves, gantries, etc. to automatically stop the motor at both ends of travel. Additional
switches shall be provided where necessary for control, interlocks and indication.

Limit switches shall be mounted suitable for easy adjustment and for rigidly locking in
position after being adjusted. They shall be of heavy-duty rating and have two
changeover contacts suitable for specified control voltage level.

Switch fixings shall be unaffected by vibration. At the same time they should be capable
of easy adjustment to suit changing parameters of the associated plant.

Particular attention shall be paid to potentially harmful environmental conditions,


including water, oil, dust, dirt, temperature variations and differential expansions.
Where switches operate through linkages, precautions shall be taken to eliminate
variations of settings and incorrect operations resulting from wear or tolerances.

7.4.9 Contact Devices


Contacts of level switches, pressure switches, temperature switches, limit switches, and
of all other devices shall be of the snap-action type (SPDT). Contact devices for
interlocking systems shall be separate, i.e., contact devices serving commonly for
interlocking and other purposes will not be accepted.

7.4.10 Vibration measurement


The measuring equipment has to comply with requirements stated in IEC 60994 and
ISO 10817-1.

7.5 Interlocking and Lockout System


The Interlocking and Lockout Systems shall be provided for all Works components and
individual systems to ensure a safe and reliable Works operation and to limit harm and
damage to personnel and Works to an utmost extent.

These devices shall facilitate the duty of the operating staff and prevent incorrect
operation.

7.6 Tests
The single components and pre-erected assemblies shall undergo functional and routine
tests in the Contractor's or Sub-Contractor's workshop. The ready mounted control and
supervisory system shall undergo functional tests on Site prior to commissioning of the
Works.

Calibration tests shall be made on all important instruments and measurement devices as
required by the Employer.
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8 TRANSPORT AND INSTALLATION

8.1 General
For shipping, loading, transportation, unloading, and storage appropriate period shall be
considered.

The delivery dates, transportation and erection periods indicated in the Contract
Documents shall be strictly adhered to. Changes which are unavoidable or necessary
will be regulated in accordance with the stipulations laid down in the General
Commercial conditions of contract.

The Contractor shall provide the Employer with complete packing lists of each
performed shipment.

8.2 Packing
The Contractor shall prepare all plant, devices and materials for shipment to protect
them from damage in transit, and shall be responsible for and make good all damages
due to improper preparations, loading or shipment.

After the workshop assembly and prior to dismantling for shipment to the Site, all items
shall be carefully marked to facilitate site erection. Wherever applicable, these markings
shall be punched or painted so they are clearly visible.

Dismantling shall be done into convenient sections, so that the weights and sizes are
suitable for transport to Site and for handling on the Site under the special conditions of
the Project.

All individual pieces shall be marked with the correct designation shown on the
Contractor's detailed drawings and other documents (packing lists, spare part lists, in
Operating and Maintenance Instructions, etc.).

Marking shall be done either by labeling or by punching the marks into the metal before
painting, galvanizing, etc., and shall be clearly legible after painting, galvanizing etc.

All parts of the Works shall be packed at the place of manufacture; the packing shall be
suitable for shipment by sea and for all special requirements of the transportation to
Site. Enough strong containers, cases or boxes shall be used in order to prevent damage
and corrosion during transportation, unloading, reloading or during intermediate
storage.

All identical members shall be packed together, if reasonably possible, in a form


convenient for shipment and handling.

Small items shall be packed in boxes and large items shall be protected, where
necessary, by timber, straw and sacking. All bolts, nuts, washers, etc. shall be packed in
containers. Each container shall include only bolts, nuts or washers of identical size.

All parts shall be suitably protected against corrosion, water, sand, heat, atmospheric
conditions, shocks, impact, vibrations, etc.
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All electrical parts shall be carefully protected from damage by sand, moisture, heat or
humid atmospheric conditions by packing them in high pressure polyethylene foil.
Where parts may be affected by vibration, they shall be carefully protected and packed
to ensure that no damage will occur while they are being transported and handled.

The Employer reserves the right to inspect and approve the packing before the items are
dispatched but the Contractor shall be entirely responsible for ensuring that the packing
is suitable for transit and such inspection will not exonerate the Contractor from any
loss or damage due to faulty packing.

All packing costs are part of the scope of work.

8.3 Marking
The Contractor shall mark all containers with the implementing document number
pertinent to the shipment. Each shipping container shall also be clearly marked on at
least two sides as follows:

Consignee : XXXXX

Contract No. : XXXXX

Port of destination : XXXXX

Item number (if applicable), Package number, : XXXXX


in sequence and quantity per package

Description of Works : XXXXX

Net and gross weight, volume : XXXXX

8.4 Transport and Storage


The Contractor shall inform himself fully as to all relevant transport facilities and
requirements, loading gauges and other limitations and shall ensure that the equipment
as prepared for transport shall conform to such limitations. The Contractor shall also be
responsible for obtaining from the local railway or highway authorities any permit that
may be required for the transport of loads exceeding the normal gauges.

The Contractor shall provide means for all unloading and reloading for all consignments
of plant, both during transport to Site and on the Site. Consignments shall be unloaded
immediately on arrival at Site. The Contractor is required to take the necessary steps in
order to provide the carriage, special supporting structures for heavy loads, etc.

All parts of the plant shall be brought, as far as possible, to their final place of erection.
The Contractor shall construct its own storage facilities at site.

The warehouse shall be weatherproof, with good ventilation and solid floors. The floors
of the storage areas shall be designed to carry the loads imposed on them by the stored
parts. The following parts shall be stored indoors:
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Bolts, pins, packing, tools, insulation materials, electrical parts with electrical devices
attached, electric motors and excitation equipment, instruments, welding material and
equipment, all small parts and all parts of the plant which already have been finally
painted.

If large (mechanical) parts are stored in the open air, they shall be provided with
weather resistant and fire-resistant covers. Electrical parts which are not packed in
heavy duty polyethylene foil and those so packed but whose packing has been damaged
shall be kept in suitable indoor places from the moment of storage up to the starting of
installation.

All insulation materials which will be taken from the storage for installation and which
are stored temporarily in the station shall be protected from weather and humidity.

All the equipment shall be stored as per standard storage and preservation instructions
etc. of the suppliers.

8.5 Preparation and Installation


Prior to commencement of installation, the Contractor shall closely inspect the site and
all the foundations and other structures on which parts of the plant supplied under this
Contract will be installed; he shall check that the foundations conform to the installation
drawings.

The result of this check shall be reported to the Employer in due time to allow any
errors to be corrected before the commencement of erection. All parts of the plant shall
be cleaned carefully of all contamination such as dust, sand, rust, mill scale and other
dirt prior to installation.

8.6 Reference Points


The Employer will provide major center lines and datum levels only. The Contractor
shall be responsible for transferring those required to carry out the Works. The
Contractor shall employ a competent surveyor for setting-out of all datum lines
including the constant checking and maintenance of the setting-out until the completion
of his works.

The Contractor shall provide all necessary pegs, profiled templates and center lines and
shall establish all such permanent markings and recovery marks as may be required by
the Employer for checking the Contractor's setting-out. The Contractor shall be
responsible for rectifying, at his own cost, all work rejected by the Employer due to
errors in setting-out.

All bench marks, notch marks, pegs and signals on the surface, alignment pins and the
like put in by the Employer for the purpose of checking the Contractor's work or as
permanent survey marks will be under the care of the Contractor during the period of
the Contract. He shall, at his own expense, take all proper and reasonable care and
precautions to preserve and maintain them in their true position where such marks are
within or adjacent to his work area. In the event of their being disturbed or obliterated
by any cause whatsoever, they may, if so determined by the Employer, be replaced by
the Employer at the Contractor's expense.
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The Contractor shall be responsible for the true and proper staking-out of the works and
levels of reference given by the Employer in writing, for the correctness of the
positions, levels, dimensions and alignment of all parts of the works and for the
provision of all necessary instruments, appliances and labor in connection with this.

The checking of any staking-out or of any line or level by the Employer shall not in any
way relieve the Contractor of his responsibility for its correctness.

8.7 Installation Works


All transportation and handling of the plant from the place of storage to the place of
installation shall be carried out by the Contractor. He shall provide all hoisting
equipment, staging and scaffolding, winches and wire ropes, slings, tackles and all other
appliances and temporary materials. The erection staging and scaffolding shall be
provided with coverings and barriers and shall guarantee safe working conditions.

The Contractor shall comply with all applicable and approved safety regulations while
carrying out the works on Site and with all reasonable requirements of the Employer.
This stipulation shall in no way release the Contractor from any obligation concerning
his liability for accidents and damages. He shall be responsible for adequate protection
of persons, plant and materials against injuries and damages resulting from his
operations.

The plant or parts to be installed shall not be overstressed during the process of
installation.

The Contractor shall be responsible that the installation of all plant is properly executed
to the correct lines and levels and in accordance with the manufacturer's instructions and
the Contract requirements.

The alignment of the plant shall be done in accordance with the tolerances indicated by
the Manufacturers, drawings or given by standards.

Setting of parts to be aligned shall be performed by means of fine measuring


instruments. All erection clearances and settings shall be recorded. Copies of these
records shall be given to the Employer. After alignment, the parts shall be held firmly in
position by means of set pins, fitted bolts, etc.

Anchor bolts, baseplates, anchor rails, etc. to be embedded in the first stage concrete
shall be delivered in due time with instructions and/or templates to facilitate the
bringing in of such parts into the Civil works.

All parts to be embedded in concrete shall be set accurately in position and shall be
supported rigidly to prevent displacement during the placing of concrete. Adjusting
screws and bolts shall be drawn tight and secured adequately. Steel wedges shall be
secured by welding. Wooden wedges shall not be used.

The Contractor shall verify carefully the position of all parts to be embedded before
concrete is poured. All important measurements and dimensions shall be recorded.
Copies of these records shall be given to the Employer for checking and approval before
items are built-in to the Works.
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The Contractor shall be responsible for the supervision of the building-in work. He shall
state the allowable concreting or grouting rates and any required sequence for pouring
in the different places. After concreting, the control measurements shall be verified
again, indicated in the above mentioned records and submitted to the Employer.

Any error in shop work which prevents the proper assembling and fitting of the parts
shall be immediately called to the attention of the Employer and approval obtained for
the correction procedures.

The Contractor shall provide all necessary anchors and braces to ensure the alignment
and stability of the parts to be installed. All temporary anchors and bracings shall take
care of all dead load, wind load, seismic and erection stresses, e.g., during concreting,
and shall remain in place until they can be removed without endangering the stability of
the plant.

If for installation purposes auxiliary structures have been attached to the plant, they
shall be removed after completion of work and the surface restored to proper condition
by grinding and repainting.

Special care shall be taken not to damage surfaces of galvanized or specially treated
plant during erection. Care shall be taken to prevent or remove any rust streaks or
foreign matters deposited on galvanized or otherwise finished surfaces during storage or
transport or after installation.

Glass parts or other parts which can easily be damaged shall be provided with suit-able
protective sheaths or coverings during installation.

Machined or bare metal surfaces which are to receive no coat of paint shall be protected
during transportation, storage and erection by a suitable anti-corrosion film.

All power tools preferably are operated pneumatically. They are to be handed over at
the end of the installation work in good condition in accordance with the Employer's
instructions.

After erection, the works shall be finally painted, in accordance with the painting
specification, and any damaged paintwork shall be restored.

The Contractor shall keep the site in clean condition during erection and commissioning
time. On instruction of the Employer he shall remove waste from the place of
installation to the defined deposit site at his own cost.

8.8 Civil Site Work


The following works shall be carried out as part of the civil works contract and is not
included within the scope of work covered by the Particular Technical Specifications:
• All concrete work, including reinforcement and formwork, and all grouting required
for filling in, around and under the various parts of the works to be embedded in
concrete.
• All necessary excavation and backfilling required for installing the plant in its final
position, unless otherwise stated in the Particular Technical Specifications.
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• Building in of all required parts into the first stage concrete. The readiness of such
parts shall be communicated to the Employer and they shall be delivered in due time
by the Contractor unless otherwise specified or agreed in the Contract.
• Providing and grouting the blockouts for all anchoring and foundation bolts needed
to support and fix the plant in its final position.
• All protective measures, e.g., pumping, etc., to keep the various parts of the plant
and the erection site free from water during the time of erection.
• Provision of cable and pipe ducts, trenches, block-outs, etc., in accordance with the
drawings supplied by the Contractor and supervised by the Contractor.
• Adequate safety covers and protective measures against injury or damage to the
Contractor's employees and equipment and to the works due to any operations of the
civil contractor.
• If checkered plates or other covers provided under the civil contract require special
care for fitting to plant and installations, such work (cutting, matching, welding of
supports, etc.) shall be performed by the civil contractor.

8.9 Safety Precautions


Prior to starting any work the Employer through the civil work contractor shall supply
and fix in suitable positions near the work concerned large multilingual temporary signs
and markings written in local language(s) designated by the Employer and in English
giving clear warning of danger in areas which might previously have been regarded as
safe.

The Employer through the Package 1 contractor shall provide all temporary scaffolding,
ladders, platforms with the boards and handrails essential for safe and convenient access
to the working areas by workmen, inspectors and other authorized persons employed for
the Works.

All dangerous openings or holes in floors shall be provided with handrails or covers.
Preventive measures shall be taken to protect workmen from falling material.

The maximum possible safety shall be afforded to personnel directly engaged on this
Contract, those who frequent the working area or those who in the normal course of
their occupation find it necessary to utilize temporary works erected by the Employer
through the civil work contractor.

Working on energized electrical equipment is prohibited.

8.10 Fire Protection and Fire Fighting


The Contractor shall be responsible for the fire protection of his buildings, working
areas and storage rooms by providing trained personnel and fire fighting equipment.

Sufficient fire fighting equipment shall be provided on the Site for the full period from
the commencement of site works until take-over of the Works.

The Contractor shall ensure that both he and his Subcontractors take all precautions to
prevent fires occurring. In particular the following fire prevention measures shall be
taken:
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No open fires shall be allowed within the site area. Burning of condemned materials
shall be carried out in a specially designated area outside of the site area.

Combustible material shall be stored in places where spreading of fire is limited to a


minimum. Non-combustible plastic foils shall be used for protection of material.

All combustible material shall be removed from working areas where the work going on
requires the use of or produces open flames (e.g. welding). If such removal is
impossible, the working area shall be specially protected by suitable fire fighting
equipment.

The Contractor shall maintain the fire fighting equipment fully operational at all times
and shall recharge extinguishers after use regardless of by whom they were discharged.
Adequate stocks of fresh chemical charges for use in extinguishers shall be kept in
readiness on the Site.

The Contractor shall nominate certain of his employees who shall be made available for
initial training in fire fighting duties and subsequently for fire fighting drill and
servicing of fire fighting equipment. The nominated employees shall be available for
fire fighting duties at all times when they are on the Site.

8.11 Cleaning Up
Throughout the duration of the Contract the Contractor shall maintain the Works in a
clean and tidy condition.

All material not in use and/or no longer required for the Works, all condemned
materials and all rubbish shall be removed from the Site, combustible rubbish shall be
removed daily.

Upon completion of the Works, the Contractor shall remove all Temporary Works
which he may have constructed for the protection of plant or his convenience while
carrying out the works and all equipment and surplus materials and any remaining
rubbish which may have accumulated in the execution of the Contract and shall leave
the whole area in a clean and tidy condition.
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9 INSPECTIONS AND TESTS

9.1 General
All equipment, including all materials, components, apparatus, etc. called for in these
Specifications while in the process of manufacture and during installation and
commissioning will be subject to such tests and inspections as required by pertinent
standards, as may be the standard practice of the manufacturer and as deemed necessary
by the Employer to prove compliance with the requirements of these Specifications.

Approval of assemblies, tests, inspections, related procedures, etc. shall in no way


relieve the Contractor of his contractual obligations for furnishing the Works in
accordance with the provisions of these Specifications.

The Contractor shall be responsible for the execution of all inspections and tests
required to demonstrate during manufacture and on completion that the equipment
complies with the requirements of the Specifications. The cost associated with all such
inspections, checks and tests shall be borne by the Contractor.

The Contractor shall prepare an inspection and test program including all tests during
and after manufacture (except for stock material) which shall form part of the Contract
and which shall describe the inspections and tests for each major component and item.
The program shall include a sufficiently detailed manufacturing schedule with all
expected dates of inspections and tests, a description of each inspection or test
(including the test method) to be performed and the applicable standards. Where
Contractor's acceptance standards are proposed, copies of same shall be provided for the
Employer's approval.

The inspection and test program and the related schedule shall be up-dated by the
Contractor at two month intervals with clear indication of revised inspection and test
dates.

Written notice of the exact date, time and place of inspections and tests to be attended
by the Employer, as well as all other necessary information shall be given to the
Employer in writing not later than 14 days prior to the date of any such inspections and
tests.

Free and unrestricted access to the Contractor's factory and shops (including those of his
Subcontractors) shall be granted to the Employer upon reasonable notice at all times.

Should an agreed inspection not be feasible as proposed due to lack of preparation,


negligence or material and/or equipment being presented in a state which is clearly not
acceptable, all costs incurred for the Employer and/or his delegate(s) for repeated
inspections shall be fully borne by the Contractor.

9.2 Test Certificates


Test records, test certificates, performance curves, tables, etc. of all inspections and
tests, whether or not attended by the Employer, shall be supplied as soon as practicable
after performance of each inspection or test. After completion of all testing the above-
mentioned documents shall be supplied properly bound in books.
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All test certificates shall be endorsed with sufficient information for identification of the
equipment and material to which the certificates refer. In addition, the following
references shall be entered in the top right hand corner:
• Employer's name
• Project name
• Equipment designation (e.g. Governing System)
• Related Contractor's drawings (No.)
• Date of test
• Certificate issue date

9.3 Testing
Inspection and testing of the equipment shall comprise, but not be limited to:
• Mechanical and chemical testing of materials
• Destructive and non-destructive tests of materials
• Checks and examinations of welds
• Checks of fits and assemblies
• Dimensional checks
• Inspection of paints and coatings
• Hydrostatic pressure and tightness tests
• Balancing tests
• Electrical tests
• Running tests (including measurements of vibration and noise)
• Functional tests
• Pressure and Leakage Test
• Performance tests
• Load and overload tests
• Load rejection and load taking-up tests
• Acceptance tests

These tests will be carried out principally as defined in the inspection and test plan.

The techniques, equipment and instrumentation to be used for these tests, checks,
inspections, examinations, etc. shall be in accordance with internationally accepted
standards, rules or codes, and in particular those mentioned in these Specifications.

If the Employer should justify that the instruments, apparatus, devices, etc. used by the
Contractor (or his Subcontractor) require re-calibration, he has the right to request this
to be done at the Contractor's cost.

(1) Random Sample Tests


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Random tests shall be carried out on random samples of a lot of equipment, parts or
material. Selection of samples to be tested will be done by the Employer and all the
equipment, parts, etc. shall be presented for this purpose. The number of samples taken
will be either at the discretion of the Employer, particularly for smaller lots, or shall
conform to the generally accepted rules and standards of statistical testing.

Should a single sample fail during random sample testing then the following shall
apply:

a) Small lots: all pieces shall be fully tested

b) Large lots: a second set of samples, identical in number with the first one, shall be
chosen and tested. If this set passes all tests satisfactorily, the lot shall be considered
to be acceptable. If again one or more samples fail in one or more tests either the
whole lot shall be rejected or all pieces of the lot shall be fully tested individually, as
determined by the Employer.

Pieces of lots which have been declared unacceptable and samples which have failed in
test shall be marked immediately and shall not be presented for test again.

(2) Non-Destructive Testing

Radiographic, ultrasonic, magnetic particle or liquid penetrating tests shall be conducted


on components as appropriate. Where ultrasonic or magnetic particle tests indicate the
possibility of a flaw, the suspect part shall be tested by radiography. All flaws shall be
removed by thermal or mechanical gauging processes and replaced by welding. The
replacement weld and contiguous parts of the original weld if any shall then be tested
radiographic method. All radiographs shall become the property of the Employer.

9.4 Tests at Manufacturer's Works

9.4.1 General
Before any material, equipment, apparatus, component etc. is packed or dispatched from
the Contractor's or his Subcontractor's works all tests, inspections, checks,
examinations, etc. required by pertinent and internationally accepted standards, rules or
codes shall be carried out as far as practicable and agreed in same parties' premises.

All materials, apparatus and other parts or components of the equipment to be tested,
inspected, checked, examined, etc. at the Contractor's or his Subcontractor's works shall
be made properly accessible for testing and inspection work. There shall be no
interference or disturbance from other shop activities when conducting checks, tests and
inspections.

All equipment, materials, apparatus and other parts or components shall be adequately
sheltered and protected against the weather whilst being tested, inspected, checked and
examined.

Parts and components shall be assembled to the greatest extent possible and as agreed,
and dimensional checks performed on all major assemblies, sub-assemblies, parts and
components especially when close tolerances and fits are involved (tolerance of shafts,
clearance between stationary and moving parts, connecting dimensions for assembly
with other elements and supplies, combined functioning of electrical equipment, etc.).
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Components and parts to be weld-assembled at the Site shall be tag-welded in the shops
to permit visual and dimensional checks of the fits and transitions. All such components
and parts shall be match-marked properly to ensure correct assembly and welding at the
Site.

If dimensional checks show discrepancies in measurements which may affect the fit,
assembly or dismantling of the respective part or component, proper and workmanlike
corrections or modifications shall, however, in no way lead to sacrifices with respect to
reliability of operation or interchangeability and shall only be performed with the
Employer's approval. If the correction or modification cannot be carried out in
accordance with the terms mentioned above, the part or component concerned may be
rejected.

Shop testing shall also include functional tests on partial or complete assemblies to the
greatest extent possible and as agreed. Such tests shall, as far as possible, be performed
under conditions as similar as possible to final operating conditions. When requested by
the Employer the functional tests shall be repeated or extended until proof has been
obtained that the assemblies will function in accordance with the Specifications.

Cubicles, cabinets and control boards shall, prior to their inspection and testing, be
completely and properly assembled, equipped and wired internally in the Contractor's or
his Subcontractor's shops.

9.4.2 Type Tests


Type tests shall be performed to establish the required main characteristics of the
equipment and that they conform to the requirements stipulated in the Specifications.
Type testing shall be carried out on a single item of apparatus or assembly of each type
and rating by a reputable testing institution and shall be witnessed and duly
authenticated by an internationally known independent body or by the Employer. If
there is evidence of successfully performed type tests on identical apparatus in an
independent laboratory, the respective certificates may be accepted in lieu of testing.
Such type test certificates shall be submitted to the Employer.

9.4.3 Routine Tests


Routine tests are required on all equipment items both to prove that the product is in
accordance with equipment which has been successfully type tested and to reveal faults
or defects in materials or on equipment due to inadequate or insufficient supervision
during fabrication, assembly, etc.

9.5 Tests on Completion


Equipment will be subjected to site testing during and after installation work at the Site.
Site tests shall comprise but not be limited to the testing, checking, inspection and
examination of all equipment assembled, welded and set up at the Site. The period of
site-testing and site-checking will be up to the Employers taking over of the Works.

The Contractor shall provide at his cost sufficient competent personnel (including those
of his Subcontractors) as well as all equipment, materials and other services required for
the proper and complete testing and putting into commercial service of all equipment. If
in the opinion of the Employer the personnel are inadequate the Contractor shall at the
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Employer's request and at no additional cost provide additional, appropriately


competent personnel.

Unless waived in writing all tests and checks shall be performed in the presence of the
Employer. If not satisfied with the performance or results of the tests and checks the
Employer shall have the power to ask for additional tests or repetition of the same.

9.6 Reliability Run


Immediately upon termination of the tests on completion of a section of the Works
which can operate as an independent unit or termination of complete Works, a reliability
run shall be started. The duration and further details of the reliability run is stated in
Commercial conditions of contract.

During the reliability run, the Works shall be subjected to normal operation with the
generating units connected to the network for power supply at various loads and as
required. The reliability and readiness for permanent use of the Works shall be
demonstrated by this operation. The Contractor shall make the Employer's personnel
familiar with the properties, the operation and maintenance of the Works to such extent
that after completion of the reliability run the duties can be assigned to the Employer's
trained personnel.

Should any defects be revealed during the trial operation which, in the opinion of the
Employer, shows that the reliability and readiness for permanent use or other
contractual requirements are not fulfilled, then the reliability run will be cancelled and
repeated when the defects have been corrected.
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10 STAFF TRAINING
To facilitate the reliable plant operation and maintenance after taking-over by the
Employer, the responsible Employer's staff shall be made familiar with all equipment
supplied by the Contractor and installed in the Plant. To reach this the concerned staff
shall be properly trained during the manufacturing of the equipment at the Contractor's
works.

At a later stage, during the site-erection, commissioning and trial operation periods of
the equipment, the Employer's technical staff shall be trained by the Contractor in
assembly, dismantling, commissioning and operations under supervision of the
Contractor.

The number of trainees, training schedule and duration is defined in the Particular
Technical Specification.
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11 ANNEXES
The following Annexes form an integral part of the General Technical Specifications:

Annex A Equipment Designation System -Application Guide

Annex B Forms of Data Schedules


• Motor Data Schedule (MDS)
• Feeder Data Schedule (FDS)
• Cable Data Sheet (CDS)
• Cable Laying Schedule (CLS)

Annex C Painting System

Annex D Symbols and Abbreviations


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Section 1, General Technical Specifications


Chapter 11 - ANNEXES
Annex A – Equipment Designation System (EDS)
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Introduction

General

This Application Guide is based on DIN Standard 40719 part 2 and has been prepared
mainly for use in Hydropower Plant projects. The rules described herein are presumed
mainly for designation of:

• Electrical and mechanical equipment items on diagrams, layouts and


correspondingly (with suitable labels) on the installed equipment itself
• Various power plant areas and rooms
• Power and control cables
• Terminals and signals
• Spare parts
• Drawings and schedules (if required).
Particular Project Applications

The tables shall be currently completed with relevant details and kept up-to-date by one
responsible person for the whole project (to avoid double-definitions or other
confusions).

The completed/revised Guide versions shall be regularly distributed to all parties


concerned and in the as-built form finally included in the Operation Manual.

Alpha-numeric Symbols

Various blocks/boxes have been used for description of the designation code forms.
Within these boxes "A" stands throughout the whole document for identification letter
and "N" for a number.
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Designation System Blocks

The equipment marking codes are composed as follows:

Block 1 Higher-level assignment showing correlation with other parts of the


equipment with regard to location and/or function

A supplementary designation may be assigned to an item if it is desired


to express its relation to a larger unit of a system, of which it is a part.

Block 2 Location of item

Block 3 Identification of item:


A = kind of item
B = number of item
C = function of item

Block 4 Terminal and conductor markings

Qualifying symbols are used to distinguish the Blocks 1, 2, 3 and 4 of a complete


designation. The different blocks with their qualifying symbols are shown below:

HIGHER
BLOCK 1 = LEVEL
ASSIGNMENT

BLOCK 2 + LOCATION

3A 3B 3C

BLOCK 3 − KIND NUMBER FUNCTION

BLOCK 4 : TERMINAL

The qualifying symbol may be omitted if there is no ambiguity. There can be other
symbols used in front of Block 4 to designate e.g. signals ("!"), etc.

The following sequence of designation blocks shall be used if "full identification" is


required:
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Block: 1 2 3A 3B 3C 4

HIGHER
= LEVEL + 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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Plant Identification Code (Block 1)

Sections of Block 1

The identification block is subdivided into the following 5 sections:

Section: 1 2 3 4 5

N AAA NN (A)A NN(N)


Qualifying Symbol =

Position: G1 F1F2F3 FN A1A2 A3A4

Meaning: General Function Aggregate

The individual sections can be recognized by an alternating arrangement of numerals


and letters.

The identification Block 1 has a maximum of 11 alphanumeric data positions.

The positions indicated in parenthesis can be omitted.

Complete sections only from right to the left hand side can be omitted from the codes.

The alphabetical data positions are often allotted a specific meaning, which is laid
down in tables.

The numerical data positions are used for numbering of panels, items, cables, etc.

Example

Section: 1 2 3 4 5

2 BFA 10 G 12
Code: =
12th

outgoing el. feeder (drawer outfit)

from bus section (or panel) No. "10" of

switchgear FA

for 2nd generating unit


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Location Identification Code (Block 2)

The form of identification block for "location" of electrical equipment placed in


switchboards is as follows:

Section: 1 2 3 4 5

Qualifying Symbol N AAA NN • (A)A NN

+
"•" only in Block 2 between sections 3 & 4
(to distinguish between Block 1 & 2 form)

The sections 1 and 2 are identical with Block 1.

The panels of one switchboard shall be numbered in section 3 (e.g. for bus 00 with 01,
02, 03, etc. for bus-section 10 with 11, 12, 13, etc.).

The vertical (columns) and the horizontal (row) spot identification can be described
after separator "•" in section 4 and 5 (if required).

For location identification of other electrical equipment (machines, assemblies, etc.)


the "room code" according to Section 10 here below can be used (if such
identification is required).

Equipment Identification Code (Block 3)

The "Equipment" identification block is preceded by a minus sign (-); it consists of the
parts 3A, 3B and 3C

Block: 3A 3B 3C

Section: 1 2 3

A N N (N) A (A, N)
Qualifying Symbol -
Meaning: Kind Number Function

of electrical equipment item

For equipment identification, at least part 3B must be marked in the schematic diagram
(if no confusion possible), whereas parts 3A and 3C may be added to part 3B as
supplements.

The complete cable identification code comprise the target address (Block 1) and the
cable designation (Block 3).
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Example
can be omitted

= 2 MEY 01 D 01 _ (J) 01 F

Low voltage Cable


Cable No. 1 Designation
Qualif. symbol
Motor No. 1 for
Governor oil pump Target Address
of Unit No. 2

Equipment Items Designation - Examples (Block 3)

Equipment Identification Codes consisting of a Kind Identifier and a Number

S 1 K 31 N 42

Qualifiying Symbol

Kind

Number

Equipment Identification Codes consisting of a Kind Identifier, a Number and a


Function Identifier

S 1 A T 1 L1 T 1 L2

Qualifiying Symbol

Kind

Number

Function
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Complete Equipment Identification Code – Split Representation

Identification blocks (or parts thereof) which are the same for most of the items of
equipment represented in a schematic diagram, e.g. the "Plant" identification block, are
shown only once at a suitable place in the diagram, e.g. in the block. The complete code
then comprises this common part and that which is marked next to the equipment
symbol. Items not covered by the common part are marked (at or near their symbol)
with the complete code (see in the following example: contactor contact =TB43 -K1 in
diagram =AC11. Marking of the equipment location can proceed in a similar manner.

Example:

-S3 -K3 -K4

=TB43-K1 -K8 -K9

-K3 -K4 -K5

Block =AC 11

The complete identifying codes of all other symbols in the above example would read:

=AC11 -K3, AC11 -K4, =AC11 -K5, =AC11 -K8, AC11 -K9 and =AC11 -S3.

The equipment identification codes are found

inside enclosures, on or immediately adjacent to the particular item,

in the equipment or component list, complete with additional information,

in the parts list complete with additional information that is generally required for
reordering.

Marking of Integrated Components

With integrated components, one item of equipment forms part of another, each having
its own markings, e.g. modular assembly - A1 (superordinated item) and the transformer
- T1 (superordinated item).
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Code of superordinated item

-A1

380V3~
-T1

19V3~ 19V3~

-G1 -G2

~ ~
⊗ ⊗

+24V +15V OV +15V +24V

Code of subordinated item

Fig. 11.1: Integrated item of equipment forming part of plant =M3. The modular
power pack -A1 consists of transformer -T1 and the power supplies -G1 and -G2. The
complete identification codes read: =M3 -A1, =M3 -A1 -T1, =M3 -A1 -G1, =M3 -A1
-G2.

To designate an item of equipment which forms part of a superordinated item, the two
identification blocks are joined together (that of the superordinated item being on the
left).

Example:
The complete identification code of a modular assembly consists of the "Plant" and
"Kind, Number" blocks and reads =M3 -A1. The transformer built into this assembly is
designated by the "Kind, Number" -T1 identification block (see Fig. 11.1).

The complete transformer identification code thus reads: =M3 -A1 -T1.

Additional Information

If required, the American standard designation of the protective relays and small
apparatus can be used in "Block 3" of the equipment designation code.

Technical data and type designation can be indicated below the equipment identification
code in smaller print.
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Terminal Identification Code (Block 4)

Section: 1 2 3

Qualifying Symbol : A NN(N) A(AN)

The "Terminal" block is used when


• the connections between items of equipment have been replaced by broken lines
showing target or similar symbols, as illustrated in Fig. 11.2,
• terminals located in a plant other than the one to which the schematic diagram
applies.

-11 -12 -13


1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4

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

-14 -15 -16


1 2 3 4 5 6 1 2 3 4 5 6 1 2 3

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

Fig. 11.2: Typical "Terminal" Identification


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Cable Route Designation

For description of the route in which the cables shall be laid following (special) code
combined from room identification and route section designation can be used:

Block: 1 3

Code: + AAANNANN(N) − A(N)NNA

Room Identification Route Section


(see para. 10) Designation

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

2nd Layer (from above)

Cable tray
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Room Designation

For the identification of various rooms in the power plant building (and switchyard)
following code can be used:
Section: 1 2 3 4 5

Code: + (N) A AA N N A NN(N)

Room No. (per floor)

"R" for "room designation"

Floor (from deepest to highest)

Building/Yard designation

"U" for room designation code

Unit (not applicable here)

Example

+ U BA 02 R 15

Room number

Specific letter

2nd floor

Machine hall

Specific letter
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Designation of Equipment
Additional Examples of Description and Identification Key according to DIN 40
719

In the following list only a part of ME and SC is added. Some of the main divisions
(e.g. F, and H) will not be applied for hydraulic power stations.
A Grid and distribution system
B Power transmission and aux. power supply
C Instrumentation and control equipment
D Instrumentation and control equipment
E Conventional fuel supply and residues disposal
F Handling of nuclear equipment
G Water supply and disposal
H Conventional heat generation
J Nuclear heat generation
K Reactor auxiliary system
L steam, water, gas cycles
M Main Machine Sets
ME Hydraulic Turbine Plant
MEA Turbine
From excl. turbine inlet or
from excl. isolating valve
to incl. turbine outlet or
to excl. isolating valve, incl. draft tube
MEB Isolating valve
MED Bearings
MEG Stabilizing air system
MEK Transmission gear
MEL Water depression air supply system
MES Shaft gland cooling system
MEV Lubricant supply system
N Process energy supply
P Cooling water supply
Q Auxiliary systems
R Gas generation and treatment
S Ancillary System
SC Stationary compressed air supply
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SCA Compressed air generation system


SCB Compressed air distribution system
SCC - SCU Stationary compressed air supplies
SCV Lubricant supply system
SCX Fluid supply system for control and protection equipment
SCY Control and protection equipment
T
U Structures
V
W Renewable energy plant
X Heavy machinery
Y
Z Workshop and office equipment
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Section 1, General Technical Specifications


CHAPTER 11 - ANNEXES
Annex B - Forms of Data Schedules

Motor Data Schedule (MDS)

Feeder Data Schedule (FDS)

Cable Data Schedule (CDS)

Cable Laying Schedule (CLS)


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Description Unit Data Description Unit Data Description Unit Data


CONSUMER / DRIVE / MACHINE INSTRUMENTATION

Name of drive - Permissible starts per hour under


EDS ident. No. - full load from Instrumentation diagram No.
Manufacturer - - Cold condition Nos. Resistance temperature detectors
Power demand of drive at coupling - Warm condition Nos. (RTDs), Pt 100 in stator winding
- At nominal point kW Insulation class (IEC) - (HV motors):
- At maximum capacity kW Design temperature rise of - 3x1 for temp. measurement yes/no
RATED DATA stator winding K Temperature detectors (ther-
Type designation - Thermal time constant mistors):
Type of construction (IEC 34-7) - - Heating up min in stator winding (LV motors)
Cooling method code (IEC 34-6) - - Cooling down min - 3 in series for alarm yes/no
Degree of protection (IEC 34-5) - Perm. blocked-rotor time from - 3 in series for trip yes/no
Duty type (IEC 34-1) - - Cold condition s Thermostat: in stator winding yes/no
Frame or flange No. - - Warm condition s in bearing yes/no
Rated output kW OTHER DATA
Rated voltage Un V Moment of inertia J (m.r2) kg ⋅ m2 Remarks:
Stator connection for Un Δ/Y Direction of rotation CW/CCW
Rated frequency Hz (facing the shaft end)
Rated speed 1/min Type of bearing at
Overspeed test 1/min - Drive end (DE) -
Rated current In A - Non-drive end (NDE) -
Ratio of starting/rated current Type of lubrication -
(ls/ln) at Un - Magnitude and direction
Power factor at of axial thrust (if any) N
- Rated output p.U. Number of terminal boxes for
- 3/4 rated output p.U. - Power supply -
EfficienCy at - Space heater -
- Rated output % - Instrumentation -
- 3/4 rated output % Degree of protection of terminal
Rated torque Nm boxes (IEC) -
Starting torque at Space heater Rev. Date/Signature Rev. Date/Signature
- Un Nm - Rated power W
- 0.85 Un Nm - Rated voltage V Project: Employer:
Pull-out torque at Torque-speed diagram No.
- Un Nm (motor plus load) Contractor: Manufacturer:
- 0.85 Un Nm Motor outline drawing No.
- 0.70 Un Nm Total mass of motor kg Date: Prepared by:
Starting time (motor plus load) at Placed in room No.
Starting torque at
- Un s MOTOR DATA SCHEDULE (MDS)
- 0.85 Un s
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Project: Employer:

Contractor: Prepared by: Date:

Feeder Data Schedule (FDS)

Position No. (in "List of Consumers") :

CONSUMER (EDS Identification No.):


Type (Motor, Valve, Heating, etc.) :
Description/Name (Text) :
Data Schedule (MDS No. for consumers) :
Rated Voltage (V) :
Rated Power (kW) :
Rated Current (A) :

SWITCHBOARD (EDS Identification No.) :


Feeder/Bay - EDS No. :
Feeder - Module type :
- Circuit diagram (No.) :
- Rated current (A) :
Switchgear - Type (fuse, CB, contactor) :
Protection - Type (SC/OL, EF) :
- Setting SC/OL (A) :

POWER CABLE (EDS Identification No.) :


Cable - Type (CDS No.) :
- Cross section (mm2) :
- Diameter (mm) :
Material - Conductor :
- Insulation :
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Project: Employer:

Contractor: Prepared by: Date:

Cable Data Sheet (CDS)


Position No.:
CDS No. :
CABLE-Type (HV, LV / C & I) :
Cross Section (mm2) :
Manufacturer Name/Specification No. :
Manufacturer Identification/Catalogue No. :
Rated Voltage (V) :
Rated Current (A) *) :
Armoring :
Screening :
Sheath - Material :
- Color :
Overall Diameter (mm) :
Mass (kg/m) :
Min. Bending Radius (cm) :
Max. Pulling Force (kN) :
Max. Supply Length (m) :
CORE-No. and Type *) :
Material and Type (Cu/Al, solid/stranded) :
Insulation (material) :
Ohmic Resistivity (Ω/km at 20°C) :
Inductive Reactance (Ω/km) :
Operation Capacity (Microfarad/km) :
*) Legend:
- "Rated Current": Cable single-laid in 30°C warm air, core temperature 50°C
- Core type coding: P - Phase, E - Grounding, N - Neutral
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Project: Employer:

Contractor: Prepared by: Date:

Cable Laying Schedule (CLS)


Position No. :
CABLE (EDS-Identification No.) :
Target Equipment - 1st End (EDS No.) :
- 2nd End (EDS No.) :
Cable - Type (CDS No./Make) :
- Rated Voltage(V) :
- Cross Section (mm2) :
- Length (m) :
CORE CODING AND TERMINATION *)
Core Address at Target 1 Address at Target 2 Connection
No. Color (Identification No. of terminals) Diagram No.
: : : : :
: : : : :
: : : : :
: : : : :
: : : : :
: : : : :
: : : : :
: : : : :
: : : : :

: : : : :
: : : : :
CABLE ROUTING (Tray Section EDS-No.)
**)
1 : 2 : 3 : 4 :
5 : 6 : 7 : 8 :
9 : 10 : 11 : 12 :
13 : 14 : 15 : 16 :
17 : 18 : 19 : 20 :
Remarks:
*) Cable core coding with color or with numbers printed on the insulation shall be used.
Cable cores when being connected shall be designated with corresponding terminal
identification numbers (or phase color) on both ends.
**) The corresponding EDS designated cable route sections shall be indicated on the tray layouts.
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Section 1, General Technical Specifications


CHAPTER 11 - ANNEXES
Annex C - Painting System

A Gates stoplog and trashracks incl. armatures, hydraulic hoist etc.


Internal surfaces of steel lining penstock, turbine distributes, valves and other ferrous
surfaces.
B External surfaces of penstocks, gantries, cranes, lifting beams fixed hoist supports and other
drive supports.

C External Surfaces of indoor ferrous parts such as valves, connection pipes, oil carrying tanks
and pipes, supporting structures, gantries etc.

D Control cabinet panels, cubicles, electric meters.

E Interior surfaces of oil tanks.

F Frames, cover plates, pipes and tubes and miscellaneous steel parts not especially mentioned.
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PAINTING SYSTEM

Type Description Surface Paint System Main Dry Film Remarks


Preparation Thickness in μm

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.

- Internal surfaces of steel Intermediate Coat : This paint system is for


linings, penstock, turbine 2 x micaceous iron oxide paint, 2 x 100 temperatures up to 120°C
distributor, valves and 2-component
other wetted internal Base: epoxy resin
ferrous surfaces

Finish Coat : The colors of intermediate and


1 x topcoat, 2-component 1 x 100 finish coats shall be black - brown
Base : epoxy resin - black

__________

Total 380
========

PAINTING SYSTEM
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Type Description Surface Paint System Main Dry Film Remarks


Preparation Thickness in μm

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

Intermediate Coat : This paint system is for


2 x micaceous iron oxide paint, 2 x 80 temperatures up to 60°C
2-component
Base : epoxy resin

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

Type Description Surface Paint System Main Dry Film Remarks


Preparation Thickness in μm

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.

Intermediate Coat : This paint system is for


2 x micaceous iron oxide paint, 2 x 80 temperatures up to 120°C
2-component
Base : epoxy resin

Finish Coat :
1 x topcoat, 2-component 1 x 50
Base : epoxy resin
__________

Total 260
=========
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PAINTING SYSTEM

Type Description Surface Paint System Main Dry Film Remarks


Preparation Thickness in μm

D. - Control cabinets, panels, Sa 3 and de-grease Prime Coat:


cubicles, electric motors before painting 2 x zinc chromate primer, 2-component 2 x 40
Base : epoxy resin

Finish Coat :
2 x topcoat, 2-component 2 x 50
Base : epoxy resin
__________
Total
180
=========
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PAINTING SYSTEM

Type Description Surface Paint System Main Dry Film Remarks


Preparation Thickness in μm

E. - Interior surfaces of oil tanks Sa 2 1/2 - 3 2 x thixotrop consistent paint 2 x 220


Base : epoxy resin
__________

Total 440
=========
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PAINTING SYSTEM

Type escription Surface Paint System Main Dry Film Remarks


Preparation Thickness in μm

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
__________

Total, incl. zinc 200


=========
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Section 1, General Technical Specifications


CHAPTER 11 - ANNEXES
Annex D - Symbols and Abbreviations
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Length, Area and Volume


cm centimeter
cm2 square centimeter
ha hectare
km kilometer
2
km square kilometer
l liter
m meter
2
m square meter
3
m cubic meter
mm millimeter
2
mm square millimeter
rad radian
µm micron = 10-6 m

Time and Time Derived Units


d day
h hour
Hz hertz (periods per second)
km/h kilometers per hour
min minute
mm/s millimeters per second
m/s meters per second
m/s2 meters per second squared (acceleration)
3
m /s cubic meters per second
s second
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Mass, Force and Derived Units


atm standard atmosphere = 101325 Pa
bar bar = 105 N/m2
daN deca Newton = 10 N
g gram = 10-3 kg
J Joule = 1 Nm (Newton-meter)
kg kilogram
kJ kilojoule = 103 J
kg/m3 kilograms per cubic meter
mg milligram = 10-6 kg
mg/l milligrams per liter
MPa Megapascal = 106 Pa
N Newton
N/m2 Newton per square meter
N/mm2 Newton per square millimeter
Pa Pascal = 1N/m2
t ton = 103 kg
t/m3 ton per cubic meter

Electrical Units
A ampere
kVA kilovolt ampere
kW kilowatt = 103 W
kWh kilowatt hour
MW megawatt = 106 W
V volt
W watt = 1 J/s
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Electrical Engineering Abbreviations


AC Alternating Current
CB Circuit Breaker
CDS Cable Data Sheet
CLS Cable Laying Schedule
CT Current Transformer
DC Direct Current
FDS Feeder Data Schedule
GB Gigabyte
HRC High Rupturing Capacity
HV High Voltage (cables)
I&C Instrumentation and Control
LV Low Voltage
MB Megabyte
MCB Miniature Circuit Breaker
MCC Motor Control Center
MDS Motor Data Schedule
MV Medium Voltage
NC Normally Closed
NO Normally Open
PE Protective Grounding
PEN Protective Grounding Neutral
rms Root Mean Square
SCADA Supervisory, Control and Data Acquisition
SPDT Snap Action Contact Device
TN Neutral Wire Connection
UPS Uninterruptible Power Supply
VT Voltage Transformer
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Other Symbols and Abbreviations


approx. approximately
asl above sea level
bhp brake horse power
C.I. Cast Iron
CIF cost, insurance and freight
dia. or diam. diameter
EDS Equipment Designation Schedule
fig. figure
FOB free on board
hp horsepower
horiz. horizontal
HT high tensile (steel)
H.W.L high water level
max. maximum
M.F.L maximum flood level
min. minimum
M.O.L. minimum operating level
no. number (units), as in 6 no.
No. number (order), as in No. 6
temp. temperature
vert. vertical
vol. volume
wt weight
°C degrees Celsius
% percent

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