DAKNONG ALUMINUM SMELTER PROJECT

GENERAL SPECIFICATION
OF
POTROOM

DAKNONG ALUMINUM SMELTER PROJECT

Document File Name: THQ.ALU.SPEC-001

Document Status: For Use

Authorizations
Name Function Signature

Developed By: Technical Leader

Reviewed By: Project Manager

Approved By:

Revision History
Rev Status Description Date Developed by Reviewed by
1 First 07.Jun.2022
issue
GENERAL SPECIFICATIONS DAKNONG ALUMINUM SMELTER PROJECT

Revision 1 –07/Jun/2022– Page 2 of 10

Contents
1. INTRODUCTION 4

2. DEFINITIONS 5

3. SCOPE OF SUPPLY 5

4. ENGINEERING SCOPE 7

5. GENERAL PROJECT REQUIREMENTS 8

6. DOCUMENTATION PROVIDED BY SUPPLIER 8

7. QUOTATION FORM 9

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A. INTRODUCTION:
1. General:

This General Specification deals with the materials, design, fabrication, erection,
testing of structure, equipment and component relating to the Pot room

The execution of the work, including such design and detailing as may be required
shall be performed in accordance with the specifications and standards mentioned
therein, except as otherwise directed in this specification or by the THQ Engineer.

Should the Contractor wish to deviate from any part of this specification, he shall
obtain the THQ Engineer's authority in writing before proceeding with the deviation.

All proposals, MDRs, procedures, working instructions etc… shall be in English

2. Applicable standards:

The equipment and components shall comply with the minimum requirements of the
current version at the award date of the International Codes and Standard sourced for
the following associations:
ASTM American Society for Testing and Materials
AWS American Welding Society
BSI British Standard Institute
DIN Deutsches Institut für Normung
AFBMA Anti-Friction Bearing Manufacturers Association
AGMA American Gear Manufacturers Association
ANSI American National Standards Institute
ASA American Standards Association
ASME American Society of Mechanical Engineers
FEM Fédération Européenne de Manutention
FPI Fluid Power Institute
IEEE Institute of Electrical Electronic Engineers
ISA Instrument Society of America
ISO International Organization for Standardization
SAE Society of Automotive Engineers
SSPC Structural Steel Painting Council

The Contractor have the full right to propose alterative applicable standards and seek
for the Owner’s authority in writing before proceeding and quotation.

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Incase of proposing Chinese standards, the English version shall be submitted along
with the deviation request.

B. GENERAL TECHNICAL REQUIREMENT:

1. Structural steel works:

Main material shall be ASTM, except the otherwise will be agreed by the Owner

The material certification shall comply with ISO 10204 type 3.1

The Contractor shall maintain material traceability for structural steel and all loads
bearing mechanical parts from the mill source.

All weld details shall be in accordance with the latest AWS D1.1 – an American
Welding Society Standard.

The requirements on welds and welding procedures shall meet AWS Codes.

All welding, inclusive of welding for the main structure, sub-structures, tack welding of
temporary brackets, welding of brackets for conduits and etc. shall be performed by
welders certified according to AWS requirements. All tack welders shall be certified.

Welding procedure qualification tests shall be carried out for all welding positions
employed in the fabrication process, according to AWS requirements.

Valid welders' qualification certificates and all welding procedures shall be reviewed,
approved and certified.

Non-destructive examination (NDE) shall be carried out on the welds to determine

their acceptability according to AWS requirements.

WPS/WPQ, NDE procedures shall be summited prior to start fabrication.

The Contractor shall develop the ITP and all procedures with acceptance criteria for
each ITP steps. The ITP will be submitted to the Owner for reviewing and approve.

Maintenance platforms and permanent attachments shall be provided for all position
required maintenance and periodically monitoring.

2. Mechanical equipment:

a. Equipment supports:

All drive train items including motors and gear drives shall be mounted together on a
common integral steel base plate of either fabricated or cast construction and bolted
with through bolts.

All machined surfaces shall be free of paint with and appropriate rust preventative
applied.

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Base plates shall be provided with adjusting screws for longitudinal and transverse
alignment of motors and the driving equipment.

Shims shall be provided to ensure that motor and driven equipment may be aligned
after installation

Machines without separate base frames which are located on structural steel or
concrete foundations shall have machined pads at each hold-down bolt. Machining of
these pads shall be to a common level unless the machine design necessitates the
use of multi-level pads.

b. Bearings

Bearing brands:

Bearings for mechanical equipment shall be heavy duty anti-friction ball or roller type
bearings.

All bearing selections shall be in accordance with the bearing manufacturer’s

recommendations for the given application, load and operating conditions.

All bearings, housings seals and bearing accessories shall be of readily available
standard types and sizes. The number of different sizes and types used shall be
minimized.

No mixing of bearing brands on the same system. The Contractor shall provide the
bearing list.

c. Pillow blocks

The pillow blocks shall be selected in accordance with the bearing manufacturer’s
recommendations.

Pillow block casing shall be cast iron, Pressed steel housing is not acceptable.

Adjusting bolts or wedges and shear blocks shall be provided for all bearing housings.

Lifting lugs or eyebolts shall be provided on all pillow blocks weighing in excess of
20kg.

Adjustment bolts and lock nuts shall be provided for longitudinal alignment.

Bearings shall be fitted directly to mounting pads without shims, unless shims are
necessary for alignment.

Lubrication nipples, in accordance with the lubricant section of this specification, shall
be provided unless connected to a central lubrication system.

d. Brakes:

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Brakes shall be rated at a minimum of 150% of the motor’s nominal torque.

All brakes shall be provided with a label in accordance with specification which clearly
shows at least the following:
- Manufacturer.
- Model number.
- Serial No.
- Date of manufacture.
- Torque rating (kNm).
- Brake fluid type.
- Hydraulic oil quantity if applicable (litres).
- Mass (kg).

e. Drives:

Chain drives:
- Chain drives shall only be used for low speed, high torque applications.
- All chain drives shall be properly lubricated.
- All chain sprockets shall be made of hardened steel. Teeth and hubs shall be fully
machined.
- Chains drives shall be provided with adequate take-up facilities. The installation and
take-up allowance shall be strictly in accordance with the chain manufacturer’s
recommendations

Chain drives belts:

- All chain drives shall be provided with a label in accordance with specification
which clearly shows at least the following:
o Equipment No.
o Chain manufacturer and designation
o Oil specification
o Oil quantity (litres)

f. Coupling:
- Coupling selection and service factors shall be in accordance with the coupling
manufacturer's recommendations with due regard to the application and drive duty.
- The minimum service factor shall be 1.5 based on installed motor power. In addition,
couplings shall be selected to have a torque capacity of at least 125% of the
maximum torque that can be developed under all starting, braking, stalling or
transient operating conditions.
- If lubrication is required, couplings shall be fitted with grease nipples to permit
lubrication of the couplings without dismantling them.
- Safety guards covering the couplings shall be made of expanded metal and fitted
with hinges to facilitate maintenance. Additional for visual inspection and
maintenance purpose one inspection door is required. All coupling guards shall be
closed at both ends.
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g. Gear Reducers:
- Speed reducers shall be the manufacturer’s normal design, selected for the service
life and the technical requirements specified.
- All gearing shall be designed for a service life of 65,000 hours at the design load
unless otherwise specified.
- Unless otherwise specified, service factors shall be selected in accordance with the
gear manufacturer’s recommendations, but shall always be greater than 1.5 the
times motor power.
- Gears shall be mounted on shafts that are supported by bearings on both sides of
the gear. Shafts shall be sized to minimize deflection and maintain accurate gear
alignment.
- The input shaft and all components shall be capable of either clockwise or anti-
clockwise rotation. The replacement of individual gears and bearings shall be
possible with a minimum of interference to other components.
- Gear casings shall be to the manufacturer’s proven design, and shall be oil tight,
water tight, dustproof and of robust design.
- All gears shall be totally enclosed in leakage free, rigid, oil-bath casing.
- All gears shall be factory tested at the OEM site and test report or certificate
submitted to the Buyer.
- All gears shall be designed for silent operation. The OEM factory test reports
including the noise level generated shall be provided.
- Gears shall be factory inspected and tested for its dimension, teeth thickness,
surface hardness, backlash value and no load test, as a minimum.
- Oil level indicator and dial type oil-filled temperature gauge shall be provided on
every gear reducer for visual inspection. These indicators shall be located for ease of
inspection.
- All gearboxes shall come with drain outlet for easy oil/grease replacement.
- Two- directional jacking bolts should be provided for alignment purposes.
- All gears, speed reducers and gearbox/drive assemblies weighing over 20kg shall be
equipped with appropriate and properly designed lifting lugs or eyes for attaching
lifting slings for installation and maintenance. Such attachments shall be placed so
that the equipment remains horizontal when lifted.
- All gear reducers shall be provided with a label in accordance with which clearly
shows at least the following:
o Equipment No.
o Manufacturer.
o Model No.
o Serial No.
o Date of manufacturer
o Actual gear ratio
o Input speed (rpm)
o Output shaft direction of rotation relative to the input shaft
o Mechanical rating (kW)
o Oil spec
o Oil quantity (litres)
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o Mass including oil (kg)

h. Lubricant system:
- Where required, centralized greasing systems shall send the necessary quantity of
grease to each grease point during the lubricating cycle.
- For lubrication points that are not connected to the centralized lubrication system,
proper routing must be done to enable greasing at convenient and accessible
locations.
- Grease nipple(s) for manual greasing shall be made available at all rotating parts,
including those with an auto-grease system connected.
- All grease lines and branch grease lines shall have bore diameters of not less than
12 mm shall be formed by joining short pipes of appropriate length which can be
easily disconnected at the joints to facilitate the clearing of grease blockage and
replacement of damaged sections of pipes.
- All other lubrication points that are not connected to the centralized lubrication
systems shall be routed by tubing and grouped together at convenient, accessible
locations for easy application of grease.

3. Hydraulic system:

The hydraulic system shall be designed to withstand the impact and shock of the
operations.

All hydraulic components, valves, piping, fittings etc. shall be easily available and
represented by a local agent in the Owner’s country.

The Contractor is to include a feature to detect a leak in the system. This feature will
be able to cut off the system and prevent the hydraulic fluid from draining.

The cleanliness, quality and operating viscosity of the hydraulic oil must be maintained
within the system to ensure operating reliability and long service life.

The Contractor shall provide adequate filters to remove any contaminants that may be
present in the hydraulic oil.

An oil sampling test to be passed (according to standards) before acceptance.

The hydraulic system shall be designed to withstand the harsh environment and
operating conditions specified.

Accessibility of the hydraulic components including pump, motor, valves, etc. shall be
provided for ease and safe maintenance environment.

Filtration system shall be adequate to maintain a specific level of cleanliness

recommended by the OEM in accordance to their assessment of the application. The
filters shall be equipped with indicators to indicate dirty filter element conditions.

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Hydraulic systems shall be flushed until a specific level of cleanliness is achieved. Test
by means of an electronic particle counter shall certify the oil cleanliness. Method to
flush the hydraulic system will be submitted by the supplier, to be approved by the
Owner

First oil change of the hydraulic system, including the supply of oil recommended by
the OEM, shall be done by the manufacturer. This first oil change interval shall be
proposed by the Contractor. This is to be performed in front of the Buyer’s personnel.

Before filling the system with hydraulic fluid, it is to be ensured that the hydraulic fluid
is as specified and that it is clean. Cloth strainers shall not be used nor fluid that has
been stored in contaminated containers.

Hydraulic-powered units installed in the casthouse and potrooms shall be equipped

with pressure transmitters that shut-off the units in the event of a sudden loss of
pressure in the high-pressure system.

Pressure and flow adjustment points on hydraulic units shall be located in safe and
easily accessible places.

Adjustment devices shall be equipped with positive locking mechanisms.

Hydraulic pumps shall be automatically stopped under the following conditions:

- Operation of the emergency stop (hardwired contact).
- Loss of oil pressure.
- Excessive oil pressure.
- Excessive oil temperature.
- Low oil level.
- Heat detection in the Hydraulic room

Reservoirs:
- Reservoirs of hydraulic power units shall be designed to provide maximum protection
against oil contamination.
- Reservoirs shall be equipped with filter complete with indicator.
- Reservoir openings shall be designed such that they are protected against the
ingress of dirt and foreign fluids.
- Return lines to the reservoir shall be located as far away as possible from the suction
lines.
- Reservoirs shall be provided with an appropriate internal baffle system to prevent the
system return fluid to form a vortex and to allow sufficient time for air bubbles and
contaminants to dissipate. The baffle plates shall be installed close to the bottom and
reaching up to the oil level.
- The inlet and outlet connection of the tank shall be flange-type.
- The bottom of the reservoir shall be slightly sloped to ease the elimination of
accumulated water.
- The reservoir shall be marked with normal level, minimum level, oil type, system
capacity and reservoir capacity.

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Pressure Gauges:
- Pressure gauges shall be supplied with an accuracy of ± 1%, to indicate maximum
working pressure and discharge valve adjustments. The dial shall be in SI units with
a diameter from 100 mm to 115 mm. The operating pressure range shall be clearly
marked on or adjacent to the gauge.
- The gauges shall be mounted so that they can easily be read and are protected from
impact and vibration. For additional protection from vibration, liquid gauges may be
used.
- Gauges shall be provided for the pump outlet pressure and at all positions in the
system, where the pressure can be adjusted or the control gauge with selector switch
for various measuring positions can be used. A push button unit shall be installed for
reading and relief of the central gauge from continuous pressure.
- Pressure gauges shall be provided with isolating valves and shock absorber.
- Operating pressure shall be within 50 to 60% of the gauge scale.

Individual components must be labelled to the schematic drawings.

The Contractor shall ensure that the hydraulic system components are accessible
without dismantling piping or other equipment to gain access for maintenance.

The Contractor shall label all hydraulic lines, hoses, valves, pumps etc at both ends of
all the connections, at the manifolds, reservoirs etc.
General requirements for testing:

- The Vendor/Contractor shall perform testing during fabrication on all components /

subassemblies and / or complete assemblies in accordance with the specified
technical standards.
- The Vendor/Contractor shall also assemble the complete hydraulic facility so that
shop testing of pressure, performance and noise levels along with the verification of
the correctness of fabrication, fit and dimensional accuracy can be carried out. The
Vendor/ Contractor shall carry out the shop running tests by connecting the power
pack to the hydraulic equipment with a piping run equivalent to the installed condition
or an equivalent hydraulic test load.
- The Vendor/Contractor shall provide, for testing purposes, hydraulic fluids, temporary
tubing, electrical circuits, controls and even motors, if required.
- All hydraulic piping systems shall be pressure tested in accordance with the
appropriate British standards and shall be performed prior to commissioning.
- The Vendor/Contractor shall provide the equipment for testing purposes, only after
having ensured that the equipment has been manufactured in conformity to the
requirements specified herein and to the specified standards.
- The Vendor/Contractor shall, if necessary, provide supervision at the site for start-up
and in-service testing.
- Acceptance of shop tests does not constitute a waiver of the requirements to be met
during the on-site testing under specified service conditions.

4. Electrical and cabling:

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All wiring and cables shall be sized in accordance with the requirement of IEE and IEC
and relevant local standards in Vietnam.

All electrical installations shall be adequately earthed for electrical safety and for
protection of electrical equipment against transient voltage surges

All cabling requirements shall also apply to all electrical system suppliers

All wiring and cables shall be insulated and sheathed with material having flame
retardant properties

All layout of wiring in the control cubicles shall be designed to prevent spreading of fire

Single strand wire is not acceptable. Fine, multi-strand wire cable, which have high
bending fatigue life shall be used.

All cables shall be protected from the sharp edges of the structure and junction boxes.
At areas where the cables comes into contact with sharp corners of steel structures or
sharp edges of material, the cables shall be protected by wrapping

All cables shall be run in conduits, trunking, ducting and supported by clips at
appropriate spacing

Minimum cable bend radius shall not be less than 30 times the wire diameter

All Cables shall be laid in orderly manner and according to the requirements of the IEE
regulations

Every cable shall be properly marked at both ends with permanently hot-stamping the
identifications onto PVC sleeves

The numbering of the cables shall be properly documented and shall be consistent
and easy to interpret. Numbering system of the cables shall be systematic such that
maintenance staff can easily identify the location, function or electrical system of a
cable through the number

5. Control panels and junction boxes:

Panel shall be completely enclosed and doors and access panels shall be equipped with
seal joints, and shall comply with the following requirements:

- Junction boxes: IP 66, corrosion resistant Stainless steel, with hinged door ad
provided with drain fittings.
- Local control panels: this type of cabinet is generally located in the field and shall be
IP 64.
- Remote I/O cabinets: This type of cabinet can be located either in the electrical
rooms or in the field. Cabinets located in electrical rooms shall be rated IP 52 while
cabinets located in the field shall be IP 64

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- PLC cabinets: This type of cabinet can be located either in the electrical rooms or in
the field. Cabinets located in electrical rooms shall be rated IP 52 while cabinets
located in the field shall be IP 64.

Components mounted inside panels and connections shall be laid out such as to facilitate
access for inspection, troubleshooting and maintenance purposes

All panel materials used, cable, wire, etc… shall be non-flammable

On the plant process floor, outside layout of panels shall be oriented toward an easy
operation and a quick understanding of process conditions at any given time.

Components or instruments mounted internally or externally shall be properly supported to

avoid ay vibration.

Burrs and sharp edges shall be removed. Edges and corner shall have a minimum bending
radius. If required, sleeves and covers shall be used to avoid cable cuts.

Free standing control panels shall be provided with internal lights ad door activated panel
lighting.

Wiring shall be installed in cable ducts. As much as possible, instrument wiring and power
cables shall be installed in separate cable ducts.

6. Automation:

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C. MANUFACTURERS and SUPPLIERS:

The EPC contractor can proposed manufacturers and suppliers and seek for the Owner’s
approval before proceeding.

No. Components Preferred by the Proposed by Remark

Owner Contractor
1 Motors ABB
Siemens
SEW
2 Gears/Reducers Eurodrives
SEW
3 Pillow block and SKF
bearing FAG
NSK
4 Hydraulics system Rexroth
5 Valves
6 Automation Siemens
Honeywell
Rockwell

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