° NAM MO 2 POWER COMPANY LIMITED » Go 88, Nongbeuk-Tay village, Sikhottabong district, a Vientiane Capital, Lao PDR Saar BASIC DESIGN): (FINAL REPORT)% VOLUME V-PART3 SPECIFICATION OF HYDRO-MECHANICAL AND ELECTRO-MECHANICAL EQUIPMENT SCI CONSULTING JOINT STOCK COMPANY 3rd Floor, Tower C, Golden Palace Building, Me Tri Road, Me Tri Ward, Nam Tu Liem District, 1la Noi, Viet NamBr 6 _ NAMMO2 POWER COMPANY LIMITED : Sd 88, Nongbeuk-Tay village, Sikhottabong district, Vientiane Capital, Lao PDR BASIC DESIGN (FINAL REPORT) VOLUME V - PART 3 SPECIFICATION OF HYDRO-MECHANICAL AND ELECTRO-MECHANICAL EQUIPMENT TECHNICAL MANAGER : NGO VU AN DESIGN MANAGER SCI JOINT STOCK COMPANY co PHAN ex : oN Ne HA NOI- VIET NAM, 11-2023Basie Design Nam Mo 2 Hydropower Project General informations BASIC DESIGN DOCUMENT LIST. Appendix - Hydraulic calculation of Civil works Volume IV.1 - Part 2 _ Appendix - Stability calculation of Civil works Volume IV.1 - Part 3 | Appendix - Structure analysis of Civil works Volume IV.1 - Part 4 1 Summary report (2 | Votume Main report 3_| Volume TI Design criteria 4 | Volume iT-Part1 | Drawings of Civil works Drawings of Hydro-Mechanical and Blectro- 5 | Volume Il - Part 2 Drawings TEM) eevinana (HM) 6 | Volume IV.1 - Part 1 7 8 9 Appendix - HM and EM equipments calculation 10 | Volume IV.2 - Part 1 Appendix - Report on Topography survey iL Volume IV.2 - Part 2 Appendix - Topography maps 12__| Volume IV.3 - Part 1 Appendix - Report on Hydrology and Meteorology study 13 ‘Volume IV.3 - Part 2 Appendix - Report on Reservoir Sedimentation and Backwater calculation 14 | Volume IV.4 Appendix - Report on Hydropower calculation 15 Volume IV.5 - Part 1 Appendix - Report on Geology investigation 16 | Volume IV.5 - Part 2 Appendix - Geology drawings 17 Volume IV.5 - Part 3 Appendix - Driling cores, borchole logs and testing results in the boreholes | 18 Volume IV.5 - Part 4 Appendix - Report on geophysical investigation 19 | Volume IV.5 - Part 5 Appendix - Testing results in Lab 20 | Volume IV.6 21 Volume IV.7 Appendix - Report on Hydraulic model experiment Appendix - Report on Seismic Hazard Assessment 22 Volume V - Part 1 Specification of Civil work 23 | Volume V - Part 2 Volume VI 26 | Volume VIL S CI Design Manager Technical Manager Hoang The Vinh Ngo Vu An | Specification of Earth and Rockfill dam Reservoir operating procedure Estimating downstream inundation in case of flood discharge and dam breakBasic Design Nam Mo 2 Hydropower Project General informations INVOLVED PERSON IN THE BASIC DESIGN 1 | Pham Van Nghia Deputy y General Director of SCI Group - General 3 Nguyen Tai Son vate of SCI PMC - Advisor of Civil 4 | Hoang The Vinh Deputy Director of SCI PMC - Design manager 5 |Ngo Vu An Deputy Director of SCI PMC - Technical manager 6 | Ngo Duy Manh Design leader of Main dam and Auxiliary dam 7 | Phan Van Huan Design leader of Spillway and Waterway 8. | Neuyen Thi Dieu Chinh Desi leader of Powerhouse and Monitoring 9 | Tran Minh Khoi Design leader of Construction organization 10 | Vu Duy Hung Design leader of Civil work structure 11 | Pham Van Cuu Design leader of Electrical equipments 12 [Do Manh Cuong Design leader of HM and EM equipments 13. | Nguyen Do Nhat Senior engineer of Topographic survey 14. | Tran Van Vi Senior engineer of Geological investigation 15. | Bui Van Thom Expert of Seismic hazard assessment 16 | Le Van Nghi Team leader of Hydraulic model experiment 17 [own isin Yen | eam ei of ite Svein 18 | Dau Trang Kien Sesion engineer of Hydrology and Meteorology 19. | Tran Kim Chau Expert of PMF flood estimation 20 | Hoang Xuan Chien Expert of Hydropower calculation SCI Design Manager Technical Manager Hoang The Vinh Ngo Vu AnBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment SCI CHAPTER Al GENERAL REQUIREMENTS TABLE OF CONTENTS ALJ. — General Project Information AL.1.1. Project Location and Purposes A1.1.2. Project's Main Parameters. AL2. Site Ambient Conditions. Climatic Conditions. Water A12.3. Seismic Conditions. AL3. Construction Service Conditions. A13.1. Access to Site and Transportation Conditions Ald. — The Arrangement of Equipment... ALS. Application Standards, ALO. Associated Works A1.6.1. Interface and Connection AL7. Documents to be Provided by the Contractor AL7.1. General AL7.2. Drawings... A173. Specifications... A1.7.4. Lists and Schedules A175. Calculations... A1.7.6. Operating and Maintenance Instructions. ALS, — Spare Parts AL9. Installation and Maintenance Tools... A110. Packing, numbering and storage... A111, Guiding of Installation, testing and CALIBRATing at Si A112. Operator Training A1.13. Testing... AL.13.1, General. 1.13.2. Documentation of Tests and Inspection: Design Manager | Technical Manager Design by Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment A1.13.3. Acceptance of Tests A1.13.4. Factory Tests... A1.13.5. Site Tests. 22 23 25 A114. Equipment’s Labels... 6 AL.14.1. Manufacturer's Nameplates... 26 AL.14.2. Functional Plates/ Labels. 26 A1.14.3. Supply of Warning Notices, labels and Rating Plates... 26 AL15. Surface Treatment and Painting... 26 26 27 29 31 4B 5 AL.15.1, Documents. AL.19.2. Surface preparation. A1.15.3. Coating application. AL.15.4. Coating system: A1.15.5. Quality Control (QC) AL16. Noise. S CI Design Manager | Technical Manager Design by Al-2 Hoang The Vinh Ngo Vu An Do Manh CuongBasie Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALL. ALLL. ALA2. ‘sc CHAPTER AL GENERAL REQUIREMENTS GENERAL PROJECT INFORMATION Project Location and Purposes Nam Mo 2 project is located on Nam Mo River, Xiangkhouang province, Democratic Republic of Laos. Nam Mo 2 HPP is a multi-purpose project with the following main purposes power generation by adding 120 MW capacity to the national grid at an annual average energy level of 505.58 GWh; Project’s Main Parameters I_| Project risk level Extreme 11 | Basin and hydrology 1_| Basin area at dam site (Frs) km? 280 2__| Average annual rainfall (Xo) mm 1850 Total annual evaporation loss 3 mm 465 (AZ) Average annual inflow at dam) on site (Qo) 5 _| Inflow modulus at dam site (Mo) | I/s/km* 34.71 ual vol ¢ Total annual volume of f flow) 4.1 306.53 (Wo) 7__| Design Peak flood (IDF =PMF) | mi/s 5194 UL | Reservoir 1 water level incase | 1307.60 flood PMF discharge (MFL) 2__| Full supply level (FSL) m 1305.00 3__| Minimum operating level (MOL) | m 1287.50 4 | Gross volume (Wis) Milm? 80.03 6 | Active volume (Whi) Mil.m® 67.93 Design Manager Technical Manager Design by Al-3 Hoang The Vinh Ngo Vu An Do Manh Cuong a ANS WatBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment SCI Hoang The Vinh Ngo Vu An 5_| Inactive volume (We) 12.10 7_| Area at FSL 6.14 IV _| Hydropower parameter 1 | Total capacity (Nin) ee 10% 2 | Guarantee discharge (Qa») m/s 6.45 3. | Maximum discharge (Qmax) m/s 21.02 4 | Maximum head (Hax) m 759.81 7_| Minimum head (Hain) m 718.50 8 | Average head (Hw) m 741.23 9 | Calculation head (Hu) m 718.50 10 | Guarantee capacity (Nav) MW 42.65 11_| Rainy season energy (Emm) Gwh 280.919 12_| Dry season energy (Bm) GWwh 224.661 13. | Average annual energy (Es) GWh 505.580 14 | Annual utilization hour (hax) Hour 4213 yy Main Project's components seale 1 | Main Dam Structure Earth Rock Fill Dam Dam crest level m 1311.5 Maximum height m 48.8 ‘Total length along to crest axis m 178 Crest width m 10 Upstream slope 12 to 1:25 Downstream slope L:LS to 1:2to 1:2.5 2 | Saddle (Auxiliary) Dam Design Manager | Technical Manager | Design by ALA Do Manh Cuong é i 1 ‘Basic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment Type/Structare Earth Rock Fill Dam Dam crest level m 1311s ‘Maximum height m 268 Total length along to crest axis m 145.0 Crest width m 10 Upstream slope 1:25 Downstream slope 1:2 to 1:2.5 3 | Spillway Type Practical profile Structure CVC Discharge capacity m/s 4065 Ontside and at Location right bank of main dam ‘Number of operating valve gate Tot 03 Shape of operating valve gate Radial ‘Width of operating valve gate m 10.00 Height of operating valve gate m 14.00 Threshole elevation m 1291.00 Bucket elevation m 1276.00 Type of energy dissipation Scour hole Des levation of scour hole 7 1240.00 4 | Diversion tunnel Outside and at Location, right bank of main - dam Number of tunnel o1 Design Manager | Technical Manager Design by —— T AL-S Hoang The Vinh Ngo VuAn Do Manh Cuong ; v 3 tBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment Total length m 160.13 x Inlet bottom elevation m 1263.50 Outlet bottom elevation m 1252.85 Cross section shape D shape Dimension of cross section (W x 6.0m x 6.0m x HxD) 6.0m ‘Number of inlet valve gate Lot o1 5 | Intake Outside and at Location right bank of main dam Structure cve Total length m 14.00 Bottom threshole elevation m 1274.00 Top threshole elevation m 1281.00 | ion "oF ona Dimension of operating valve Lx34mx3.tm gate (nx W x H) Dimension of repairing val mension of repairing valve gate Ix34mx4.om (@xWxt) | Dimension of trashrack (n x W x 1x58mx7.0m | H) 6 | Environmental discharge pipe In the right Location adjacent pier of spillway Type Steel pipe Total length m 57.50 Tnlet/Outlet bottom elevation ™ 1285.70/1282.50 Dimension of pipe (n x D) 1x DN500 ‘Number of operating valve Lot a1 SCI Design Manager Technical Manager Design by ots Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mu 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment _ ‘Number of repairing valve Lot oa | 7 | Headrace tunnel Total length m 4139.89 0% 1%; 5.5% Slope along to the axis 5 165 5.5% 8% Cross section shape D shape Dimension of cross section (W x 3.4m x 3.7m x Hx D) for concrete lining part 3.4m. ension of cross section (W x 42m x43mx Hx D) for shoterete and non- ni 42m lining part gy Awsiliary tunnel (for vertical shaft construction) Total length m 932.68 Slope along to the axis -8.04% to -9% Cross section shape D shape Dimensi ‘ imension of cross section (W x 4.0m x 4.3mx H x D) for shoterete and non . 4.0m lining part g Auciliary tunnel Nol (for headrace tunnel construction) Total length m 552.63 Slope along to the axis 48% Cross section shape D shape Dimension of cross section (W x 4.0m x 4.3mx H x D) for shoterete and non- ‘40m lining part - - wy Aesiliary tunnel No2 (for pressure tunnel construction) Total length m 1441.66 — = oo | S Cl Design Manager Technical Manager Design by CAL? Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment SCI Slope along to the axis 1%; 2.65% Cross section shape D shape Di ; jimension of ross section (W x dom 43mx H x D) for shotcrete and non- 4.0m lining part ‘ 11_| Vertical shaft Length of part 1 m 198.00 Length of part 2 m 222.36 Cross section shape Cireslar Inside diameter m 4.0 12_| Pressure tunnel Total length m 2729.90 Length of steel lining m 1393.50 Slope along to the axis % | 0% 1%; 10% Cross section shape D shape Dimension of non-steel_ lining 4.2m x 4.3m x section (W x Hx D) 4.2m 2.1m to 2,25m to Inside diameter of steel pi side diameter of steel pipe a 13 | Powerhouse Vest Turbine type etical shaft elton turbine Maximum tail water level incase | 552.90 flood (P=0.1%) = | Maximum tail i jaximum tail water Tevel incase | 54.00 | Quine max _| Minimum tail water level nimum tal water Tevel incase | sao.78 Quurbine min Elevation of turbine injector m 545.00 Number of injector injector os Design Manager | Technical Manager Design by ALB Hoang The Vinh Ngo Vu An Do Manh Cuong t i 4 ]Basic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment s Number of unit units 02 Dimeter of Runner (D1) m 1.868 Elevation of service bay m $99.10 Elevation of generator floor om 555.70 Dimension at EL.555.70 (W x L) 29,35m x 42.20m 14 | Tailrace box culvert Length of box culvert m 442.65 Elevation of beginning/ending m | 539.40/538.10 | Dimension of box culvert (W x 2smx3.5m Slope along to the axis of box uet 0.3% 15 | Switch yard On the top of Tneation tailrace box culvert Tyre Opened Dimension of plan (W x L) 46.2m x 60.5m Elevation of base mn 555.5 S CI Design Manager Technical Manager Design by Hoang The Vinh Ngo Vu An Do Manh Cuon; WatBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment Al2. AL2A1. A122, A123. A13. AL3.1. a) A14. SCI SITE AMBIENT CONDITIONS Climatic Conditions The climate of the Nam Mo 2 HPP area is typically tropical monsoon and changed seasonally. Water Analysis results of the underground water chemical contents has defined that the water is of weak corrosion (Ia) according to Vietnamese Standards TCVN 3994-85. Seismic Conditions All equipment shall be designed to withstand earthquake loadings at level 7 (to MSK-64). CONSTRUCTION SERVICE CONDITIONS Access to Site and Transportation Conditions Altemative: By Roadway From Hai Phong port, goods shall be transported to the Site by roadway along the following routes: = Along National Road N° 5 from Hai Phong to Ha Noi: 108km; - From Ha Noi ~ Cau Treo Border Station (Huong Son Town, Ha Tinh Province): 410km; - Cau Treo Border Station — Muong Moc Town: 278km. THE ARRANGEMENT OF EQUIPMENT The adjustment of installation dimensions of equipment in accordance with the Request of quotation shall be based on the performance and dimensions of the equipment provided by the Contractor. ‘The main dimensiors, which shall not be changed in any case, are: a. Turbine settings; b. Distance between central line of the units; ©. Length and width of the Powerhouse; d. Crane span; Design Manager Technical Manager Design by AI-10 Hoang The Vinh Ngo Vu An Do Manh Cuong a yBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALS. ALG. ALGL. qa) scl APPLICATION STANDARDS The design, material, manufacture, erection, testing, inspection and performance shall comply with the latest edition of approved standards, The latest edition of standards and Codes of Practice published by the following organizations of standardization are considered approved standards for the works: = ISO International Standardization Organization; = IEC International Electrotechnical Commission, - DIN German Industrial Standards, - VDE German Electrotechnical Commission, - BSI British Standards Institution, - ASTM Amecican Society for Testing Materials, - ANSI Amecican National Standard Institute, - AWS American Welding Society; - IBEE The Institute of Electrical and Electronics Engineers Inc., - NEMA National Electrical Manufacturers Association, - NFPA National Fire Protection Association; - ASME. The American Society of Mechanical Engineers, - TCVN Vietnamese Standards - SIS Swedish Standard Institution. - EN EuroNorms; - HIS Japanese Industrial Standard. A small selection of useful approved standards is listed below as extracted from the above-mentioned standards. ASSOCIATED WORKS Interface and Connection Supply interface and connection for equipment, pipeline, cable, etc. a, The interface between the auxiliary system pipeline supplied by the Contractor and equipment pipeline supplied by the other contractor is at | Al-iI | Design Manager Technical Manager Design by Hoang The Vink Ngo VuAn Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical ard Electro-Mechanical Equipment 2) @) SCI the position of the first couple of flange connected with main pipeline, this flange and connecting parts for the flange shall be supplied by the Contractor, the position of flanges shall be subject to the Employer’s approval. The imterface between the 22kV disconnector supplied by the Contractor (auxiliary power supply system) with local transmission line (existing) is at the connecting terminal of disconnector. The interface between 0.4kV and 220V DC station service supplied by the Contractor and cable supplied by the other contractors is the terminal of 0.4kV/220V DC distribution cubicle supplied by the Contractor. The interface between the equipment supplied by other contractor and control/protection system supplied by the Contractor is at the terminal box or control box or local control cubicle of equipment supplied by other Contractor. The equipment supplied by the Contractor shall be connected with the station earthing system nearly, connecting line, connection terminal and connecting parts. and the Contractor shall supply ‘The equipment supplied by the Contract shall be connected with the communication ports of equipment supplied by the other contractor. General definitions for interface of civil works ‘The interface between the Contractor and Civil Works Contractor is at the equipment foundation supplied by the Contractor, including anchoring, bolts, embedment, etc,, The Employer shall be responsible for the coordination working, and the Contractor shall cooperate with the Employer. The civil works Contractor shall be responsible for the conereie placement. After the completion of the foundation of the civil works for the equipment installation, the Contractor shall be responsible for supervising drilling holes in equipment foundation, leveling, chisel and other finishing work. Related work under other contracts The Contractor shall assist with the following jobs from other contracts; a, b. Embedment of parts and concrete placement in foundation work; Connection, matching and linking up of electrical/mechanical equipment to equipment furnished by others; and coordination in erection, field test, Design Manager | Technical Manager Design by Al- Hoang The Vinh Ngo Vu An Do Manh Cuong iBasie Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro Mechanical Equipment ALT.2. scl commissioning test, acceptance test and Reliability trial operation of the equipment furnished under the contracts other than this Contract. DOCUMENTS TO BE PROVIDED BY THE CONTRACTOR General The documents as defined under this Sub-Section comprising drawings, diagrams, schedules, calculations, operation and maintenance manuals and other information shall be submitted by the Contractor to the Employer in a number, quality, type and within a period as stated in this Chapter or in the Conditions of the Contract. ‘The Employer reserves the right to request from the Contractor additional documents as may be required for proper understanding and definition of construction and operation, and for other purposes such as coordination between Contractors. Documents shall be written in the language specified in the Contract. “Preliminary drawings” means drawings to be provided by the Contractor to the Employer for review and comment. “Final drawings” means all approved drawings embodying all design ‘modifications as approved by the Employer. “As built drawings” means drawings showing the arrangement of the Works in its final and complete state as installed or will be installed at the time of acceptance of the Works, The Instructions to Bidders specifies the documents to be supplied and the required status, namely "FOR APPROVAL (A) or "FOR INFORMATION ()", respectively. Any comment given by the Employer on an "T" type drawing shall have the same effect as if it were given on an "A" type drawing. Drawings All drawings shall be drawn on the International Standards Organization (ISO) “AY series of drawing sheets, standardizing where possible on the A3 and/or A2 size, Drawings shall comply with IEC60617 and ISO3272. Design Manager Technical Manager Design by Al-13 |, Hoang The Vinh Ngo Vu An Do Manh Cuong as aBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALT3. ALTA, @ @) @) @) 6) © a @) o) ao) @ Q) | SCI ‘The Contractor shall prepare and be responsible for correcting all the drawings necessary for manufacturing, supplying, delivering, installation and commissioning and guaranteeing the equipment. Besides drawings printed on paper in the form and quality specified below, The Contractor shall submit original drawings in the format *.dwg (AutoCAD file) in USBs with quantity and within time periods as specified in Form 04 of Request of quotation. Specifications Material or equipment specifications shall be prepared for all principal equipment and installations. The specifications shall state the manufacturer, place of manufacture and the relevant technical data, describe the performance (design, constructions material, dimensions, corrosion protection, etc.) of the equipment, and include a parts list. Lists and Schedules Motor Lists Motor Starter Lists Cable Lists List of Measurements Alarm Lists List of Final Control Elements Workshop Test Schedules Site Test Schedules List of Spare Parts, Tools and Appliances List of Plant Identification Numbers Calculations Design calculations, diagrams and operating data, etc. shall be submitted to the Employer with all formulae, standards, test results, basic assumptions, etc. used for these calculations. Short-Circuit Calculations Farthing Network Calculations Design Manager | Technical Manager Design by Hoang The Vinh Ngo Vit An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment G) @ AL7.6. ALS a Q) @) @ ©) © SCI Electrical Load Calculations Selection of L.V. Breakers and Minimum Cable Cross Sections Operating and Maintenance Instructions The Contractor shall provide operation and maintenance instructions, the scope of which shall be suitable for fully informing the Employer's staff on all aspects of the operation and maintenance of the equipment, as further defined in this Clause. The instructions shall be provided in draft and final forms. If the need to modify the final instructions arises, the Contractor shall provide the necessary modified content as soon as possible after the need for modification arises. SPARE PARTS The Contractor shall supply spare parts and consumable parts for all the equipment in his supply as specified in this Clause. Spare parts and consumable parts shall be provided in sufficient quantities to enable routine maintenance and routine operation of the equipment, In addition, spare parts shall be provided as replacement parts for all equipment subject to normal wear and tear and also major sub-assemblies subject to accidental damage. ‘The Contractor shall not depend on use of the spare parts ordered by the Employer under the Contract for carrying out the Contractor's obligations The Contractor shall provide a schedule of spare parts, which shall list for each spare part its identification number, description and quality with a space for the Employer to add his own identification number. The Contractor shall open the shipping crates containing the spare parts and identify the parts to the Employer. The Contractor shall then re-pack the parts for permanent storage. Each spare part shall be clearly marked or labeled on the outside of its packing with its description and tag number. In case of any failure in any original part/component of the equipment and where such failures are due to faulty design, material and workmanship, spare parts, if any, supplied for such components/parts shall also be replaced without any extra cost to the Employer. Such replaced spare parts shall have the same guarantee period in accordance with the Contract Conditions. All spare parts supplied shall be absolutely interchangeable with each other and with the parts for which they intend to replace. If the Employer observes that Design Manager | Technical Manager Design by AL-I5 Hoang The Vinh | Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment a @) SCI such interchangeability is not met to the extent required, he reserves the right to return all such parts which do not fit to the Contractor within the period of two (02) years after handing over, who in tum is to supply immediately new spare parts free of charge to the Employer. ‘The Contractor shall guarantee the long-term availability of spare parts for specially manufactured equipment for this Protect for ten (10) years and spare parts for standard equipment for five (05) years after commencement of the Commercial operation. General Spare Parts If the same spare parts are listed twice under General Spare Parts as well as under Special Spare Parts, the quantity listed under Special Spare Parts shall take priority over the quantity stipulated under General Spare Parts (reference to sub-clause A1.8(9). ‘The quantity of general spare parts as specified below shall be supplied under this Contract. General Spare Parts are classified under the following categories: a Wear and Tear Items Wear and tear items shall be defined as those, which require replacement several times during the service life of the assembly. Hence, for a number "N" of like and identical assemblies such as pump, electric motor, oil pressure unit, valve, compressor, crane, ete., "X" sets of the following spare parts shall be delivered, whereby one (01) set shall be defined as the total quantity for one (01) assembly: = Carbon brushes of generators; - Facing rings of mechanical seals; - Protection sleeves; - Carbon brushes of electric motors; - Filter insets; - Wearing bushings; - Brake liners; - Packing and seals for rotating shafts; | Design Manager | Technical Manager Design by AL-16 Hoang The Vink Ngo Vu An Do Manh Cuong _ AGNBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment Driving belts; Wearing parts of couplings frequently actuated; Springs; Pressure hoses for outdoor installation; Roller bearings for rotating shafts; Customary Spare Parts In addition to a., "X" sets of the following spare parts shall be furnished: Seals, gaskets and packing; ‘Thermometers, manometers, flow meters, level indicators (with and without contacts); Transducers 4-20mA for position, pressure, temperature, flow; Flow pressure hoses for indoor installation; Lamps, signal lamps, push buttons; Switches fuses, clamps; Limit switches, relays, pressure switches; Roller bearings, sleeves and bushings for movable parts including for spherical joints; Resistance thermometer without indicator; Motor-starters, contacts for feeder switches; Springs. For a number "N" of identical standard valves, "X" spare valves including drives shall be delivered. The following valve types shall be considered as standard: SCI Shut-off valves and cocks; Spherical and butterfly valves; Non-retum valves; Pressure relieve valves; Pressure reducing valves; Solenoid valves; Design Manager | Technical Manager Design by AL-I7 Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment - Safety valves; - Aeration and venting valve + Float controlled valves. c. Miscellaneous - Five percent (05 %) of the corresponding total cmount, but at least two (02) pieces of all bolts, screws, nuts, washers, spanner rings and cotters shall be furnished. - Five percent (05 %) of the respective quantity of painting material shall be furnished, with at least one (01) liter, in new sealed containers, for later repair work other than the Contractor's ‘The quantity "X" of the General Spare Parts to be furnished shall be a function of the number "N" of supplied like and identical assemblies. The quantity "X" shall be determined as follows: Number “NN” | Quantity “x” Remarks <3 1 ~ <10 2 _ 210 N/I0-+H | rounded up to next higher integer number In case identical assemblies are provided in a redundant arrangement, "X = 1” shall be set as the quantity irrespective of the number "N" of supplied assemblies. Parts with the following, special properties and/or sizes shall not be considered as General Spare Parts: = bolts, screws, nuts, washers, spanner rings and cotters with a nominal diameter of more than 80mm; - roller bearings, bearing shells, sleeves and bushings for movable parts including for spherical joints with an inner diameter of more than 200mm; - _ yalves with a nominal diameter of more than 600mm; - main seals for valves, access doors and openings with 2.40m in straight, length or circumference; - feeder circuit breakers. AL-18 S CI Design Manager Technical Manager Design by Hoang The Vinh Ngo Yudn | Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment (9) ALS. A110. wo Q @) SCI Special Spare Parts Spare parts defined in the Special Technical Specifications as Special Spare Parts shall be supplied under this Contract. INSTALLATION AND MAINTENANCE TOOLS ‘The Contractor shall propose special installation and maintenance equipment and tools for the proper maintenance of the equipment in his supply for the Employer's selection, PACKING, NUMBERING AND STORAGE When workshop assembly had been marked and after the workshop assembly and prior to dismantling for shipment to Site, all items of machinery and equipment shall be carefully marked to facilitate site erection. Wherever applicable, these markings shall be punched or painted so they are clearly legible. All individual pieces shall be marked with correct designation shown on the Contractor's detailed drawings and other documents (packing lists, spare part lists, Operating and Maintenance Instructions, etc.,). All equipment shall be effectively protected against damage (including all deterioration) during transport from the place of manufacture to Site and during storage en-route to Site. Large parts shall be supported to distribute their mass uniformly and thus avoid any permanent deformation. Dismantling shall be done into convenient sections, so that the weights and sizes are suitable for transport to Site and for handling on Site, under the special conditions of the Project as specified in Clauses Al.3.1 and Annex Al2. Alll identical members shall be packed together, if reasonably possible, in a form convenient for shipment and handing. All parts shall be suitably protected against corrosion, water, sand, heat, atmospheric conditions, shocks, impact, vibrations, ete. in comply with the original Contractor’s recommendation and methods of transportation. Drums shall be used for electric cables, steel ropes, steel wires and similar materials. All bolts, nuts, washers, ete., shall be packed in containers. Each container shall include only bolts, nuts or washers of identical size. Design Manager | Technical Manager Design by AL-i9 Hoang The Vink Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment @ () ALLL. a @) @) @ SCI 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. Hermetically wrapped sensitive machinery or electrical equipment shall be protected from dew water, e.g. by enclosing silica-gel bags. Machined surfaces shall be protected against corrosion. Parts on which final alignmert and running clearances depend shall have adequate blocking to prevent cistortion of their machined surfaces, and shall be positively prevented from coming into contact with timber packing or supports, paying due regard to movements which may occur during transport. If machined surfaces show signs of damage on receipt of shipment, the corrosion protection shall be removed, the rust and moisture eliminated, the defects repaired by approved means ard the protection re-applied, ‘The Contractor shall provide detailed information on the procedures and conditions of storage at Site during the erection of equipment. All packing costs shall be included in the Request of quotation Price. The packing materials shall remain the property of the Employer. GUIDING OF INSTALLATION, TESTING AND CALIBRATING AT SITE The Coniractor shall assign experienced Instructors to be generally responsible for giving instruction to the installation, testing and calibrating of his supplied equipment in accordance with the Conditions of Contract. The Instructors shall be competent to advise on all technical matters and erection procedures conceming the Plant. The Contractor shall provide a detailed unit starting program for the Employer's approval as well as take part in and assist the start-up and acceptance testing of each machine. The Employer shall provide the Contractor with time schedule for installation, testing, commissioning, trial run and acceptance. On such basis, the Contractor shall manuals for instruction and installation and arrange Instructors according to the specified time schedule. Any error in shop work, which prevents the proper assembling and fitting of the parts, shall be immediately brought to the attention of the Employer and approval obtained for the correction procedures, Design Manager | Technical Manager Design by | Al-20 Hoang The Vink Ngo Vudn | DoManh Cuong F v 4Basic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment 6) © ALI2. @ 2 @) @ SCI For each major equipment item, the Contractor shall prepare and submit to the Employer checklist forms, documenting all inspection and pre-commissioning data, Before the Employer puts any plant or equipment into operation, the Contractor is responsible for satisfying himself as to the correctness of calibrated instrumentation and of all connections between the plant and equipment supplied under his Contract and plant and equipment supplied under any other contract The Employer will not be responsible for any costs and other needs of the instructors, i.c., accommodation, meals, transportation, travel, insurance, daily expenses, ete. The Contractor shall include all instructor costs in the Bid Price. OPERATOR TRAINING ‘The Contractor shall instruct the Employer’s nominated staff in the operation and maintenance of the equipment. Such instruction shall be at Site and shall include lectures and demonstrations as required. The Contractor shall satisfy himself and the Employer that the Employer’s staffs are fully capable of operating and maintaining the equipment before leaving Site, The cost of these services shall be included in the Request of quotation Price. If the Employer so requests in writing, the Contractor's Site Representative shall remain at Site for further instructing the Employer’s staff in the operation and maintenance of the equipment for a period not exceeding three (03) months after the temporary acceptance of the relevant section of the equipment, Payment for this service shall be not included in the Contract Price. The Employer will not be responsible for any costs and other needs of the instructors, i.e., accommodation, meals, transportation, travel, insurance, daily expenses, etc. The Contractor shall include all instructor costs in the Request of quotation Price. The duration for employing Instructors of the Contractor shall be decided by agreement between the Employer and the Contractor according to actual Site conditions. Design Manager | Technical Manager Design by Al-211 Hoang The Vink Ngo Vu An Do Manh Cuong 1 } ABasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment AL ALI3.1. A113.2. ALI3.3. SCI TESTING General The Contractor shall provide all facilities, equipment and goods, including appropriate standard instruments and other measuring devices, required for carrying out the factory tests and the costs for such tests shall be included in the sums for the supplied items. ‘The Contractor shall, upon giving reasonable notice, grant the Employer free access to his workshops, and afford full facilities for unrestricted inspection and witnessing of assembly and tests and shall furnish him with such information as may be required. Documentation of Tests and Inspections ‘The Contractor shall in due time to execution of the work submit to the Employer a detailed test and inspection plan for all tests to be performed, both in workshops and at Site. ‘The test and inspection plan shall be subject to approval by the Employer. The Contractor shall, whenever, prepare appropriate test/inspection procedures required for satisfactory performance of tests and inspections and for each type of testinspection to be performed in workshop or at Site. The test and inspection procedures shall be issued to the Employer for approval in due time, but no later than three (03) months before the date of the test/inspection. Acceptance of Tests Should the tests and inspections prove that any materials or components are of unsatisfactory quality or dimension according to the Technical Specifications, the Employer shall have the right to demand any additional tests, as may be required. The related costs shall be borne by the Contractor. Approval of assemblies, tests and test procedures, etc., and acceptance of, pertinent test certificates, or waiving of inspections and tests, shall in no way relieve the Contractor of his contractual obligations for furnishing the works in accordance with the provisions of the Contract, Design Manager | Technical Manager Design by Al-22 Hoang The Vinh Ngo Vu An Do Manh Cuong reBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Ilydro-Mechanical and Electro-Mech ALI3.4. AL13.41. AL13.4.2. Q Q) B) scl ical Equipment Factory Tests General Type, sample and routine tests shall be performed according to the relevant specified standards. The Contractor may offer type test results for identical equipment and provide evidence to prove the similarity of the equipment tested and the Contract equipment. In such case, the Employer may waive the type tests for the specified equipment. Type tests shall demonstrate reliability by: - Mechanical endurance tests; - Long time high voltage tests; - Short circuit tests; - Other relevant tests, Any tests required by the Statutory Regulations of the country of design and manufacture shall be included. A written notice of the time and place of all shop tests shall be given to the Employer at least 4 (four) weeks in advance, in order that he may be present if he so desires. In addition, the following stipulation for factory inspections and tests shall epply. Material Tests Material Certificates shall be issued according to approved standards as for example EN 10204, 3.1.B / 3.1.C (DIN 50049). All principal castings and forgings, e.g. those castings and forgings subject to high service stress, impact, fatigue, or vibration stresses, shall be subject to the following tests and inspections: Chemical Analysis Mechanical Tests ‘Non-Destructive Tests (NDT) Design Manager | Technical Manager Design by Al-23 Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume ¥- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment AL13.4.3, ALI3.4.4, ALI3.4.5. ALI3.4.6. ALI3.4.7. SCI Welding Tests The standard of welding works shall be in accordance with the approved welding procedures, according to EN-288 “ASME Boiler and Pressure Vessel Code” Section VIII, Division 1, or equivalent standards, and according to AWS code ("Standard Qualification Procedure") as applicable. Inspection of Dimensions and Finish Dimensional checks shall be performed on all major parts, components and partial assemblies, especially when close tolerances and fits are involved (tolerance of shafts, between stationary and moving parts, connecting dimensions for the assembly with other supplies, ete.).. Dimensions shall be carefully checked in according to approved procedures and applicable standards as ISO-Norm R286, IEC norms ete. Inspection of Surface Treatment All surface treatment shall be subject to the relevant tests and inspections as specified in Clause A1.15 “Surface Treatment and Painting”. Factory Assembly As a general rule, all equipment shall be fully assembled in the workshop after shall, during factory assembly be temporarily fixed by tack welds. The equipment manufacturing, and where applicable prior to painting. All site welds shall be checked and approved with regard to dimensions, tolerances and alignment. Functional test shall be made wherever possible. Pressure and Leakage Tests Unless otherwise specified or required, the following shall apply regarding pressure and leakage test of all concemed equipment within the Contract: All parts subject to internal or external pressure or containing any liquids or gases temporarily or permanently during operation shall be pressure tested prior to painting, As far as practicable, these tests shall be done in the factory but can be repeated at Site, The hydraulic pressure test shall in general be carried out using the liquid to be used during operation or a liquid with less viscosity. The pressure test shall be executed by applying the test pressure in accordance with the relevant standards and Specifications. The test procedure is subject to the Employer’s approval. Design Manager Technical Manager Design by Al-24 Hoang The Vink Ngo Vu An Do Manh Cuong gBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment AL.13.48 Functional and Operational Tests Functional tests shall be defined as tests of the function of assemblies, sub- assemblies or parts of the equipment under no load conditions. As far as practicable operational test shall be carried out on all equipment, simulating operating conditions. A1.13.4.9. Electrical Tests Electrical equipment shall be tested in accordance with applicable Standards and agreed test program and procedures. When applicable, tests shall be carried out in accordance with the relevant IEC recommendations. A1.13.4.10. Model Tests Model tests for certain parts of the work or equipment shall be carried out where specified, and according to requirements made for the particular equipment (turbine for example). A1.13.5. Site Tests The Contractor shall conduct the guiding of tests at Site in accordance with these Clauses and the Contract requirements. AL13.5.1. Scope of Tests ‘The tests to be carried out and passed before acceptance of the works by the Employer shall be deemed to comprise three main stages of testing as follows: (1) Preliminary tests Preliminary tests are the tests performed during and after completion of erection but prior to rotation of, energizing at normal voltage or admission of normal water or air pressure to the main or auxiliary equipment under test. Q) Commissioning tests Commissioning tests are the tests to progressively prove the correct operation of complete auxiliary systems and of the main items. The tests shall also confirm compliance with all performance guarantees. 3) Reliability trial period Reliability trial period is in one (01) month, during which the unit shall be required to meet the load dispatch requirements of the EVN system. S CI | Design Manager | Technical Manager Design by | ‘Al-25 | Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment AL13.5.2. ALI4, AL14.1. AL14.2. AL14.3. ALIS. ALI5.1. SCI Acceptance Immediately upon successful completion of the Reliability Trial Period, the Employer will issue a Certificate of Temporary Acceptance. This document shall be signed by Employer, Consultant and the Contractor and shall form an integral part of the later acceptance of the complete Works. After successful completion of the guarantee period, the Employer will issue a Certificate of Official Acceptance to the Contractor signaling that the Contraet is complete. EQUIPMENT’S LABELS. Each individual part to be delivered under this Contract shall be equipped with permanent identification plates in readily visible locations. Manufacturer's Nameplates ‘The following data shall be shown in accordance with the relevant standards: - Manufacturer's name and address, ~ _ Equipment's serial number and date of manufacture, - Main design data, Functional Plates/ Labels Each part appearing under a certain symbol or number in functional diagrams, piping diagrams, in the Operation and Maintenance Instructions, ete., shall be equipped with a plate/label showing the same symbol or number. Supply of Warning Notices, labels and Rating Plates Failure to complete the supply and fixing of waming notices, labels and rating plates shall be sufficient reason for the Employer to withhold the issuing of Certificate of Acceptance. SURFACE TREATMENT AND PAINTING Applicable Codes and Standards are ISO 12944, ISO 8501, SSPC Vol. 1 and 2. Documents The following documents shall be developed or obtained by the Contractor prior to the start of surface preparation or application of protective evutinys: Design Manager | Technical Manager Design by Al-26 Hoang The Vinh Ngo Vu An Do Manh Cuong |Basic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment A115.2. ALIS.2.1. ALI5.2.2. SCI - Surface preparation procedures; + Coating application procedures; - _ Repair/Touch up procedures; - _ In-Process Inspection Procedure and Daily Log format. ‘These procedures shall be endorsed by the coating manufacturer prior to submission to the Employer for review. Surface preparation Pre-cleaning and preparation Prior to any surface preparation, all sharp edges to be rounded by using grinder or disc sander to approximately 2 mm radius as minimum (r> 2mm). ‘Weld spatter, slivers, laminations and other surface defects shall be removed by grinding or by the best mechanical means available and the edges smoothed or rendered flush. Mill applied vamish and pre-construction primers shall be completely removed from all surfaces prior to primer application. The only exception is for weldable shop primers, which are applied to steel sections which have been prepared in accordance with this specification and where the primer has been demonstrated to the Owner’s satisfaction to be fully compatible with the paint system to be applied. Degreasing and cleaning shall be carried out to prevent contamination of clean surfaces. Both organic (grease/oil) and inorganic (salts) mus: be completely removed in accordance with SSPC SPI - Solvent Cleaning before blast- cleaning, Blast cleaning Blast-cleaning shall be in accordance with ISO 8501-1, or equivalent to a grade of finish as dictated by the requirements for the relevant paint system listed in A1.19.5, at the time of painting. The finish shall conform to the pictorial standards shown in ISO 8501-1 and the roughness (profile) of blast-cleaned surfaces meet ISO 8503-2 unless otherwise specified in coating manufacturer's technical data sheets. Design Manager | Technical Manager Design by AL-27 Hoang The Vink Ngo Vu An Do Manh Cuong 5 \Basic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechantcal Equipment _ ALIS.2.3. ALIS.2.4. SCI Blast-cleaning operations shall not be conducted when surfaces are less than 3°C above dew point or when the relative humidity of the air is greater than 85%. Sweep blasting of galvanized surfaces shall not normally be performed. New galvanized surfaces shall be detergent washed and then etched with specialist product as supplied by the coating manufacturer. Power wire brushing shall be used on old surfaces to remove zine salts. All air used shall be free of oil and moisture and shall be delivered at sufficient pressure to achieve the required surface cleaning. Blasting particles after selected and cleaned as required shall be used once only. Blast cleaning shall not be conducted in areas close to painting operations or ‘wet coated surfaces in order to prevent dust and grit contamination, Any blast cleaned steel surface showing sign of flush rusting, condensation or contamination shall be completely re-blasted. ‘No acid washes shall be used on metal surfaces after they are blasted. This includes inhibitive washes intended to prevent rusting. Power tool cleaning Power tool cleaning shall not be used as a primary surface preparation method unless abrasive blasting is not possible due to, for example, proximity to sensitive equipment and/or surfaces, which cannot be protected. Power tool cleaning may be used for the spot repair of damaged coated surfaces and for chamfering edges of repair areas where surface preparation has been completed previously by abrasive blasting and the existing coating remains intact. Power tool cleaning shall be result in surfaces achieving the visual standard as pictorially defined in ISO 8501. Power tool cleaning shall overlap a minimum of 25 mm onto adjacent coated surfaces. Hand tool cleaning ‘The use of hand wire brushes and hand scrapers as a primary surface preparation method is not permitted. The use of other hand tools and abrasive paper is restricted to the spot repair of existing coatings or removal of near surface defects between coats. Design Manager Technical Manager Design by AI-28 Hoang The Vinh Ngo Vu An Do Manh Cuong (Basic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment AL15.2.5. ALI5.3. ALIS.3.1. SCI Equipment and Machinery If surfaces of equipment and machinery cannot be abrasive blasted without damage or contamination of moving parts or other criticel surfaces, the surfaces shall be solvent cleaned in as outlined in SSPC SPI, using liquid solvents and alkaline solutions. After solvent cleaning, the surfaces shall be cleaned by power tool in accordance with ISO 8501-1. The surface shall have a rough whorled finish and be cleaned to class St3 of ISO 8501-1 Coating application General Any procedures of coating application for surfaces to be coated shall be prepared to comply with the requirement of this specification and/or instructions, recommendations from coating manufacturer, and endorsed by the coating manufacturer prior to submission to the Employer for approval. All coating material shall be thoroughly stirred with a power mixer for a time sufficient to thoroughly mix all components. No part mixing of 2 components products is allowed under any circumstances, Coatings containing heavy or metallic pigments, which have tendency to settle, shall be kept in suspension in the application equipment by continuous agitation with a mechanical stirrer. No thinners are allowed, except where so specified by the coating manufacturer. If a coating material requires the addition of a catalyst, the pot life under application conditions shall be clearly stated on the label, or on the product data sheets, which shall available at the work place, The pot life shall not be exceeded, regardless of the apparent visible condition of the product. When the pot life limit is reached, the equipment shall be emptied, cleaned and the material discarded. Stripe coating is required to ensure sufficient coating thickness on areas which cannot be adequately coated with airless spray. Such areas are, but not limited to, behind bars and stiffeners, rough welding seams, notches, cut-outs, edges and those inaccessible to spraying. Each coating shall be allowed to dry or cure thoroughly for the specified time as per coating manufacturer's written instructions, prior to application of the Design Manager | Technical Manager Design by | 1-29 Hoang The Vink Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALIS.3.2. SCI succeeding coat. Each coat of a system shall be complete and accepted (including any repair work) prior to the application of subsequent coats. During fainting, wet film thickness of paint shall be checked frequently by gauges. Dry film thickness of each layer shall be checked by dry thickness gauge and adjusted on the same surface with the checked surface. Permissible limit for dry film thickness of each layer shall be as follows: > Minimum : 80% of specified dry film thickness. - Maximum —_: 120% of specified dry film thickness. Any area on the surface having thickness beyond the above limits shall be corrected before next layer is provided, which requires roughing the area with higher dry film thickness or supplementing paint to area with smaller dry film thickness, Painting is only performed when the temperature of steel surface at least exceeds 3°C from dewing point and relative humidity of environment does not exceed 85%, Painting must be done not later than two hours since the surface is cleaned. ‘The Contractor can provide temporary rust-preventive paint for rough steel before manufacture, after finishing of each component or each complete section. Spray application Spray application equipment shall meet the requirements and recommendations of the cating manufacturer for satisfactory application of the product. Spray guns, lines and application equipment shall be clean before adding coating material, Adequate traps shall be provided to remove moisture, oil and other contaminants between air supply and the spray equipment. The traps shall be of the automatic or continuous bleed type. Operating pressures shall comply with the recommendations of the coating ‘manufacturer, and shall be above the minimum required to obtain satisfactory application characteristics. ‘The length of material hose between pressure pot and spray gun shall not exceed 15 meters and the pot shall be placed at the same elevation as the spraying operation, Design Manager | Technical Manager Design by Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALIS.3.3. ALIS.3.4, ALIS.3.5. ALI5.4, ALAS.4.1. Each pass shall overlap the previous pass by at least 50% and surfaces shall normally have at least two passes at right angles to each other. Each coat shall be applied uniformly and completely over the entire surface. All runs and sags shall be brushed out immediately or the paint shall be removed and the coating reapplied. Brush application Coatings may only be brush applied on limited surface areas where it is shown to be impossible to spray apply, where brush application is the preferred method recommended by the coating manufacturer. Brushing shall be performed such that a smooth uniform thickness coating is obtained. There should be no deep or detrimental brush marks. Paint shall be worked into all crevices and comers. Runs or sags shall be brushed out. No extension handles shall be allowed on brushes. Other coating application methods For all coatings requiring specialist application methods or equipment, including epoxy floor coating, emulsion paint etc. application procedures shall be specifically prepared in accordance with instructions/recommendations from coating manufacturer and approved by the Employer. Repair of defects Before application of any further coat of material, all damage to previous coats shall be repaired and accepted by the Employer, coating advisor. The Contractor / Subcontractor shall prepare repair procedures for typical defects such as film defects, inadequate coating thickness, contaminated surfaces, coating damage not exposing substrate, coating damage exposing substrate etc. these procedures shall be endorsed by the coating manufacturer prior to submission to the Employer for approval. Coating systems General The coating systems listed in item A1.15.4.3 shall be applied. Coating systems deviating from this specification shall be acceptable subject to epproval.. ‘The coating systems shall be used for large components, structural steel, supporting steelworks, tanks, pipes, and equipment, except serial standard coating products e.g. valves, pumps, motors, electrical parts ete. SCI Design Manager | Technical Manager Design by AL31 Hoang The Vinh | Ngo Vu An Do Mank Cuong 2Basic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALIS.4.2. ALI5.4.3. ALIS.4.4, a) Q) Coatings from one coating manufacturer shall not be overcoated with coatings from any other coating manufacturer without specific approval from the Employer based on written confirmation of compatibility of the coating ‘manufacturers concerned, Each successive coat of a coating system shall be of a different colour tint to the previous coat except coating systems for surfaces other than steel. Color code The Contractor shall after award of the Contract submit to the Employer for approval an overall color scheme, At the request of the Employer, painting samples for the different coats and colors shall be provided. Coating systems Item Coating system Steel Structures in contact with water (penstock, sluice gates, | PS—01 lock-gate, jetties...) Steel Surfaces Exposed to outdoor atmospheric (Crane, PS ~02 outside surfaces of steel pipes...) Steel Surfaces indoor PS—03 Potable Water Tanks - Internal Surface PS-04 Steel Surfaces in contact with oil |Ps—os Steel Surfaces embedded in concrete - _|PS-06 Bolts, nuts and washers, ladders, stairs railings etc hotadip galvanizing | Inside Surfaces (submerged in water) of concrete tank PS—07 Outside Surfaces (not submerged in water) of concrete tank | PS—08 | Exterior Walls i PS-09 Interior Walls —|Ps-10 Concrete Floors | PS-11 Coating system PS-O1 Environment Corrosion category according to ISO 12944-2: Im] - Fresh water immersion. Durability ‘The expected durability is > 15 years according to ISO 12944 - 5:1998. Sc Design Manager | Technical Manager Design by AL-32 Hoang The Vinh Ngo Vu An Do Manh CuongBasic Desi n Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment @) a So ALIS.45. qa) Q) @) SCI Surface preparation Blast-cleaning to grade Sa 2% (ISO 8501-1:1988) / SSPC-SP10, using abrasives suitable to achieve a surface profile equivalent to grade Fine to Medium G (30-50 pm, Ry5) (ISO 8503-2). Shopprimer ‘Two-pack, modified low zine ethyl silicate shopprimer with solids by volume (%) 28 + 2 (chemical resistance: excellent within pH range 6-10) may be used as a preconstruction primer on blast-cleaned steel surfaces to protect steel uring transport, storage and production if required by logistical reasons, and designed to utilize extra high productivity in connection with advanced welding technology (MIG/ MAG/G-FCAW), to reduce health risk during welding & cutting, and weld defects. Dry film thickness: 15 20 microns. Coating system Product identification DET (um) Coat 1 | Two-pack zine rich epoxy primer (contains minimum 77 | 30 % zine by weight in dry film) that complies with the compositional requirements for SSPC Paint 20 level 2. Can also be made to order with ASTM D520 Type II zine dust. Minimum Solid volume is 53 + 2. Coat 2. | High solids, low VOC, high build, two-pack epoxy 450 coating reinforced with glass flakes, with extremely g00d protection against corrosion and outstanding abrasion resistance. Minimum Solid volume is 96 2, VOC should not over 40 grams/liter according to UK- PG6/23 (97). Total 480 Coating system PS-02 Environment Corrosion category according to ISO 1294-2: C3 “medium” exterior (i.e. industrial areas with medium humidity and corrosivity atmosphere) Durability The expected durability is high (i.e. > 15 years) according to ISO 12944 — 5:1998, Surface preparation Design Manager Technical Manager Design by Hoang The Vinh Ngo Vu An Do Manh Cuong 5 j tBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment @ ©) ALIS.4.6. Qo Q) (3) SCI Blast-cleaning to grade Sa 2% (ISO 8501-1:1988) / SSPC-SP10, using abrasives suitable to achieve a surface profile equivalent to grade Fine to Medium G (30-50 um, Ry5) (ISO 8503-2). Shopprimer ‘Two-pack, modified low zine ethyl silicate shopprimer with solids by volume (%) 28 + 2 (chemical resistance: excellent within pH range 6-10) may be used as a preconstruction primer on blast-cleaned steel surfaces to protect steel during transport, storage and production if required by logistical reasons, and designed to utilize extra high productivity in connection with advanced welding technology (MIG/ MAG/G-FCAW), to reduce health risk during welding & cutting, and weld defects. Dry film thickness: 15 — 20 microns. Coating system Product identification DART (um) Coat 1 | Fast drying, high solids, low VOC, two-pack zine 180 phosphate pigmented epoxy coating which may be applied in high film thickness and at lower temperature. Minimum solid volume (%) is 74 + 2. Coating interval is short (about 1 hour at 40 oC surface temperature). VOC is not over 230 grams/liter according to UK-PG6/23 (97). Coat 2 | Hardtop XP, two-pack, high solid, aliphatic 80 polyurethane coating with excellent gloss & colour retention, and solids by volume (%) 63 + 2. VOC value: 320 gms/Itr according to UK-PG6/23(97).. Total 260 Coating system PS-03 Environment Corrosion category according to ISO 1294-2: C3 “medium” interior (ic. industrial areas with medium humidity and corrosively atmosphere) Durability The expected durability is > 15 years. Surface preparation Design Manager | Technical Manager Design by Al34 Hoang The Vinh Ngo Vu An Do Manh CuongBasie Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment a 6) ALI5.4,7. @ Q) @) sci Blast-cleaning to grade Sa 2% (ISO 8501-1:1988) / SSPC-SP10, using abrasives suitable to achieve a surface profile equivalent to grade Fine to Medium G (30-50 im, Ry5) (ISO 8503-2). Shop primer Muki Z 2001, two-pack, modified low zine ethyl silicate skop primer with solids by volume (%) 28 + 2 (chemical resistance: excellent within pH range 6- 10) may be used as a preconstruction primer on blast-cleaned steel surfaces to protect steel during transport, storage and production if required by logistical reasons, and designed to utilize extra high productivity in connection with advanced welding technology (MIG/ MAG/G-FCAW), to reduce health risk during welding & cutting, and weld defects. Dry film thickness: 15 — 20 microns. Note: shop primer has to be removed before starting application of main coating system. Coating system DET ey Coat 1 | Fast drying, high solids, low VOC, two-pack zine 160 phosphate pigmented epoxy coating which may be applied in high film thickness and at lower temperature. | Minimum solid volume (%) is 74 + 2. Coating interval is | short (about 1 hour at 40°C surface temperature). VOC is not over 230 grams/liter according to UK-PG6/23 (97). Product identification Total - L260 Coat 2 | High build, two component polyamide cured epoxy 100 coating with solids by volume (%) 62 + 2. VOC is not | over 230 grams/liter according to UK-PG6/23 (97). Coating system PS-04 Environment Corrosion category: Iml - fresh water. Durability ‘The expected durability is > 15 years. Surface preparation Design Manager | Technical Manager Design by AL-35 Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electre-Mechanical Equipment Blast-cleaning to grade Sa 2% (ISO 8501-1:1988) / SSPC-SP10, using abrasives suitable to achieve a surface profile equivalent to grade Fine to Medium G (30-50 pum, Ry5) (ISO 8503-2), (4) Shop primer Muki Z 2001, two-pack, modified low zine ethyl silicate shop primer with solids by volume (%) 28 + 2 (chemical resistance: excellent within pH range 6- 10) may be used as a preconstruction primer on blast-cleaned steel surfaces to protect steel during transport, storage and production if required by logistical reasons, and designed to utilize extra high productivity in connection with advanced welding technology (MIG) MAG/G-FCAW), to reduce health risk during welding & cutting, and weld defects. Dry film thickness: 15 - 20 microns. Note: shopprimer has to be removed before starting application of main coating system, (5) Coating system Product identification I | Coat | Two-pack high build epoxy coating with high molecular weight, solids by volume (%) 54 2, It is a patt of a complete system which is certified not to spread surface flames, and APAS approved to specification 2972, VOC value: 390 gms/itr according to UK-PG6/23(97). Coat 2| Two-pack high build epoxy coating with high 100 molecular weight, solids by volume (%) 54 2. Itisa part of a complete system which is certified not to spread surface flames, and APAS approved to specification 2972. VOC value: 390 gms/Itr according to UK-PG6/23(97). Coat 3_| Two-pack high build epoxy coating with high 100 molecular weight, solids by volume (%) 54 +2, Itis a part of a complete system which is certified not to spread surface flames, and APAS approved to specification 2972. VOC value: 390 gms/ltr according to UK-PG6/23(97). Total —_ 300 Design Manager Technical Manager Design by SCI sn Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALIS-4.8. QM @) 6) @) G6) ALIS.4.9. a) SCI Coating system Coating system PS-05 Environment Corrosion category: fuel / heavy oil Durability The expected durability is > 15 years, Surface preparation Blast-leaning to grade Sa 2% (ISO 8501-1:1988) / SSPC-SP10, using abrasives suitable to achieve a surface profile equivalent to grade Fine to ‘Medium G (30-50 jum, Ry5) (ISO 8503-2) Shop primer ‘Muki Z 2001, two-pack, modified low zine ethyl silicate shop primer with solids by volume (%) 28 + 2 (chemical resistance: excellent within pH range 6- 10) may be used as a preconstruction primer on blast-cleaned steel surfaces to protect steel during transport, storage and production if required by logistical reasons, and designed to utilize extra high productivity in connection with advanced welding technology (MIG/ MAG/G-FCAW), to reduce health risk during welding & cutting, and weld defects. Dry film thickness: 15 — 20 microns, DET Product identification (um) Coat 1 | Two-pack high-build epoxy coating with high resistance | 100 to awide range of chemicals and solvents, solids by volume (9%) 50:2. Coat 2 | Two-pack high-build epoxy coating with high resistance | 100 to a wide range of chemicals and solvents, solids by volume (%) 50 2. Coat3 | Two-pack high-build epoxy coating with high resistance | 100 to a wide range of chemicals and solvents, solids by volume (%) 502 . Total 300 Coating system PS-06 Environment Corrosion category: Steel structure embedded in concrete Design Manager | Technical Manager Design by AI-37 Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment _ @ GB) a AL15.4.10. Q) Q) @) SCI Surface prepatation Blast-cleaning to grade Sa 2% (ISO 8501-1:1988) / SSPC-SP10, using abrasives suitable to achieve a surface profile equivalent to grade Fine to Medium G (30-50 um, Ry5) (ISO 8503-2). Shop primer Muki Z 2001, two-pack, modified low zinc ethyl silicate shop primer with solids by volume (%) 28 + 2 (chemical resistance: excellent within pH range 6- 10) may be used as a preconstruction primer on blast-cleaned steel surfaces to protect steel during transport, storage and production if required by logistical reasons, and designed to utilize extra high productivity in connection with advanced welding technology (MIG/ MAG/G-FCAW), to reduce health risk during welding & cutting, and weld defects. Dry film thickness: 15 — 20 microns. Coating system Product identification pee (um) Coat 1 | High build, two-pack epoxy coating based on epoxy 50 resin with high molecular weight. Solids by volume (%) 6242. Total 50 Coating system PS-07 Environment Corrosion category according to ISO 1294-2: Im1 — Fresh water Surface preparation Concrete should completely cure (28 days at minimum after casting) & concrete surface humidity should not more than 5%. Preferable methods used are “no dust blasting” or “diamond disc grinding”. Other methods can be applied are shot blast or high pressure water cleaning to achieve proper profile as recommended by coating manufacturer. Coating system Product identification bey _ - (um) Coat 1 | Penguard Clear Varnish, two-pack transparent epoxy 50 vamish with solids by volume (%) minimum 50-+ 2 & Design Manager | Technical Manager Design by AI-38 Hoang The Vinh Ngo Vu An Do Manh Cuong i \ IBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALIS41. a Q) @) SCI VOC by 420 gms/ltr UK-PG6/23(97). Appendix 3 | Coat2 | Penguard HB, two-pack high build epoxy coating with 150 high molecular weight, solids by volume (%) 54 + 2. Itis a part of a complete system which is certified not to spread surface flames, and APAS approved to specification 2972. VOC value: 390 gms/ltr according to UK-PG6/23(97). Coat 3 | Penguard HB, two-pack high build epoxy coating with 150 high molecular weight, solids by volume (%) 54 + 2. It is a part of a complete system which is certified not to spread surface flames, and APAS approved to specification 2972. VOC value: 390 gms/lItr according to UK-PG6/23(97). Total 350 Coating system PS-08 Environment Corrosion category according to ISO 1294-2: C3 “medium” interior (i. industrial areas with medium humidity and corrosively atmosphere) Surface preparation Concrete should completely cure (28 days at minimum after casting) & conerete surface humidity should not more than 5%. Preferable methods used are “no dust blasting” or “diamond disc grinding”. Other methods can be applied are shot blast or high pressure water cleaning to achieve proper profile as recommended by coating manufacturer. Coating system Product identification pee (um) Coat 1 | Two-pack transparent epoxy varnish with solids by 50 volume (%) minimum 50 + 2 & VOC by 420 gms/ltr UK-PG6/23(97). Appendix 3 | Coat 2 | High build, two component polyamide cured epoxy 150 coating with solids by volume (%) 62 + 2. VOC is not over 230 gramsiliter according to UK-PG6/23 (97). Coat 3 | High build, two component polyamide cured epoxy 150 coating with solids by volume (%) 62 + 2. VOC is not over 230 grams/liter according to UK-PG6/23 (97). Total 350 Design Manager | Technical Manager Design by A1-39 Hoang The Vink Ngo Vu An Do Manh CuongBasie Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALIS.4.12. w Q) @) @ ALIS.4.13. a) Q) @) SCI Coating system PS-09 Environment Environmental zone : high humidity and temperature. Durability ‘The expected durability is 5 years. Surface preparation All loose materials, including plaster, cement deposits, dust etc. must be thoroughly removed. Cracks must be filled up. Surfaces should be dry, clean before paint application. Coating system Product identification DET (um) Coat 1 | Acrylic water based alkali-resistant sealer with solids by | 37 volume (%) 38 1 Coat 2 | 100% acrylic weather resisting paint, possesses excellent | 39 flow and gives good smooth, tough satin finish. It is alkali, weather, algae or fungus resistant, with low dirt pick-up and good coverage. Solids by volume (%) 39 2 Coat 3 | 100% acrylic weather resisting paint, possesses excellent | 39 flow and gives good smooth, tough satin finish. It is alkali, weather, algae or fungus resistant, with low dirt pick-up and good coverage. Solids by volume (%) 39+ 2 Total 11s Coating system PS-10 Environment Environmen‘al zone: high humidity, temperature and dust. Durability The expected durability is 5 years. Surface preparation All loose materials, including plaster, cement deposits, dust etc. must be thoroughly removed. Cracks must be filled up. Surfaces should be dry, clean before paint application. , Design Manager Technical Manager Design by Al-40 Hoang The Vink Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment 4) Coating system Product identification pre (um) Coat 1 | Acrylic water based alkali-resistant sealer with solids by | 38 volume (%) 38 + 1 Coat 2. | Premium quality paint based on special modified acrylic | 36 binder with excellent flow and forms a smooth, luxurious sheen finish, Solids by volume (%) 36+ 1 Coat 3 | Premium quality paint based on special modified acrylic | 36 binder with excellent flow and forms a smooth, luxurious sheen finish, Solids by volume (%) 36 1 Total 110 A1.15.4.14. Coating system PS-11 (1) Environment Environmental zone: Light to medium duty concrete floors, floors exposed to dust, chemical or fuel oil. (2) Durability ‘The expected durability is 10 years, (3) Surface preparation Concrete must be fully cured, min. 28 days old & maximum moisture content of 5%. A proper moisture vapor barrier must have been insialled under the concrete slab. Clean using appropriate method to remove all contaminants. Oil or grease may require special treatment, Preferred surface preparation methods to remove all laitance and provide correct surface profile are blast cleaning using captive blasting unit or “walk-behind” type floor grinder. Open. abrasive blasting, scrabbling, scarifying are acceptable methods. Note: concrete substrate needs to meet minimum requirement of compressive strength, which is designed, to bear the load of each area. (4) Coating system DFT Product identification | (um) Specially formulated two-pack, epoxy resin based 100 primer used to promote adhesion between topcoats and S CI Design Manager | Technical Manager Design by Hoang The Vinh Ngo Vu An Do Manh Cuong AL-4IBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALISA4I15. Qa @) @) SCI the parent concrete substrate. It can also be applied. directly onto damp green concrete thereby aiding the curing process with solids by volume (%) 80+ 2. Coat 2 | Two-pack, high performance, self smoothing, solvent 300 free, seamless epoxy coating capable of being applied at varying thicknesses to suit the final use of the floor. It offers excellent chemical, abrasion and impact, resistance with solids by volume (%) 98 + 2. Total 400 Hot Dip Galvanizing Material For galvanizing, only original blast-furnace raw zinc shall be applied, which shall have a purity of 98.5%, according to ISO 1459. ‘The minimum average thickness of the zinc coat shall mainly be according to ISO 1461: - Forscrews, nuts and washers 375g/m?, approximately 55 microns. - For all other parts, except for steel with thickness less than Smm or for hydraulic steel structures or parts intermittently or permanently submerged in water, 500g/m?, approximately 70 microns. - For steel components of thickness between 5mm and Imm, varying linearly from 500g/mm? to 350g/m?, approximately from 70 to 50 microns. - For hydraulic steel structures or parts intermittently submerged in water, 700 g/m? or approximately 100 microns. Cleaning All material to be galvanized shall be cleaned carefully of rust, mill scale, ditt, oil, grease, and other foreign substances. Particular care shall be taken to clean slag from welded areas. Heavier components shall in general be sandblasted according to ISO 8501-1, $a2.5. Galvanizing of Hardware: Bolts, nuts, washers, locknuts and similar hardware shall be galvanized in accordance with the relevant standards. Excess zine shall be removed by Design Manager | Technical Manager Design by — Al-42 Hoang The Vink Ngo Vu An Do Manh CuongBasie Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment @) ©) ALIS. ALIS.5.1. Qo @ SCI 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, Repair of Galvanizing Material on which galvanizing has been damaged shall be redipped unless the damage is local and can be repaired by gun-spraying, soldering or by applying a galvanizing repair compound; in the latter case, the compound shall be applied in accordance with the manufacturer's instructions. Quality Control (QC) Inspection of surface preparation Surface cleanliness: After abrasive blasting, applicable to all areas: - Method : Visual assessment + Equipment/ Standard : Reference photographs in SIS 05900-1967 or ISO 8501-1. = Requirement : Min, Sa2.5 near white metal. After mechanical cleaning, where permitted only: - Method : Visual assessment - Equipment / Standard: Reference photographs in SIS 05590-1967 or ISO 8501-1 - Requirement: Min. St3 Surface profile after grit blasting: Applicable to all blast cleaned areas: - Method : Visual assessment + Replica tape - Equipment / Standard: Replica tape + dial comparator and/or surface comparator (KTA) - Requirement — : 35 to 50 microns (Rz). Design Manager Technical Manager Design by AL-43 Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ALIS.5.2. Q) Q) ALI5.5.3. SCI Inspection of painting Dry film thickness: Applicable to all painted areas, after each coat is sufficiently dry and over complete system once sufficiently dry. - Equipment Standard: Magnetic or electro-magnetic dry film thickness gauge / ISO 2808. - Requirements: As specified for each coat and completed systems in this specification in accordance with instructions of A1.15.3. Adhesion test: At the discretion of the Employer or Coating Manufacturer, on any painted area where system curing is complete. - Equipment / Standard: Pull off test (ISO 4624) and / or Cross-cut test (ISO 2409). + Requirement _ : as required by the Employer. Delivery, storage and handling All items shall be handled, stored and packed by Contractor in a manner to preserve protective coatings in the best possible condition, and to reduce the degree of repair work required. Items shall not be moved and handling shall be kept to an absolute minimum until coatings have completely cured and reached sufficient hardness to resist handling damage, generally in accordance with the coating manufacturer's curing schedule. The contractor shall furnish padding to protect coated items during shipment. Slings shall be of the fabric belt type wherever possible or shall be protected by rubber hose or a similar soft material to afford maximum protection to coated surfaces. All necessary precautions shall be taken to protect coated surfaces from damage by transport or other activities. All items shall be inspected for damage to the coating system by the Contractor on arrival of the item on site. Any damage shall be repaired in accordance with this specification. Design Manager | Technical Manager Design by Al-Ad Hoang The Vinh Ngo Vu An Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment A116. S Cl Design Manager | Technical Manager Design by | | NOISE Unless conditions specified in Technical Specifications, the noise level caused by the installed operating equipment shall not be allowed to exceed the following values: - Machine hall, mechanical workshop or any place Im maximum 804B (A) distant from operating equipment - Turbine and generator floor, outside the turbine’ maximum 854B (A) generator pits - Offices, control rooms ‘maximum 45dB (A) ~ 7m distant from diesel generator, outdoor ‘maximum 854B (A) The definition and measurement of noise levels shall be in accordance with ISO and IEC standards and shall conform to the values above. | AL-45 | Hoang The Vink Ngo Vu dn | Do Manh CuongBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment CHAPTER A2 BASIC REQUIREMENTS FOR ELECTRICAL EQUIPMENT TABLE OF CONTENTS All GENERAL. A2.1.1. Work included A2.1.2. Quality assurance .. A213. Design criteria... 422, PRODUCTS, COMPONENTS AND SUB-ASSEMBLIES A2.2.1. General A2.2.2. Corrosion protection. A2.2.3. Accessory electrical equipment. 423. EXECUTION A2.3.1. Workshop erection procedures A23.2. Site erection procedures .. S Cc I Design Manager | Technical Manager Design by Al-t Hoang The Vinh Ngo Vu An Pham Van CuuBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment — AQ. AQAL. A212. ALI. A212.2. A21.23. q) Q) CHAPTER A? BASIC REQUIREMENTS FOR ELECTRICAL EQUIPMENT GENERAL Work included This section specifies general requirements applicable to all equipment to be supplied in accordance with this package, unless different requirements are specified in the subsequent sections. Quality assurance General All items of equipment shall be designed giving due consideration to the most recent technical advances. They shall include the necessary back-up facilities to ensure reliable execution of the services specified not only during normal operating periods but also in the event of faults. Safety systems Generally, the installations shall be designed and manufactured with a view to achieving the highest possible level of safety with regard to both operating personnel and equipment, while at the same time affording access to the equipment without danger for inspection and maintenance purposes. In this respect, all components of medium-voltage circuits shall be protected from any possible accidental contact by means of solid or metal panels, latticed panel being only permissible to allow ventilation, These panels shall be provided with key-operated locks and shall be made difficult to dismantle; three keys shall be supplied for the locks. Low-voltage circuits shall be installed in such a manner that no live component comes within nommal reach, Interlocking Provision shall be made for all necessary interlocking systems to prevent potential accidental operations, Cells shall be designed in the following manner: a. Door opening shall be mechanically linked to the position of the switch and control gear so that intemal access to the compartment concerned Design Manager Technical Manager | _Design by SCI = ee Hoang The Vinh Pham Van Cun Ngo Vu An 4Basic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment @) @) A224, A225. A21.2.6. @ Q) shall be possible only if all the devices therein are disconnected and if this compartment is physically separated from neighbouring compartments possibly containing live devices. b. A cylinder lock and three keys shall be supplied by the Contractor for all cabinets or cubicles. Electrical devices shall be interlocked mechanically, electrically or by means of keys, thereby making it impossible to operate a device until all other devices on the same circuit are in a configuration allowing such operation. A general panel shall give details of all these instructions, and for this purpose shall include an explicit diagram, Dismantlability ‘The equipment shall be designed so that any item or part of the equipment can be easily dismantled for maintenance, possible repairs or handling, Dismantling and maintenance of any or all parts of electrical equipment shall be made as simple as possible, without any need to interrupt the operation of neighbouring equipment. Interchangeability - Standardisation ‘With a view to standardising the equipment installed and reducing the number of spare parts, the Contractor shall as far as possible minimise the number of appliance ratings used by including the maximum number of standard electrical and mechanical components. Interchangeability of electrical appliances of equivalent rating shall also apply to their auxiliary contacts. If certain modifications are made to the equipment during manufacture or erection, these modifications must be approved by the Engineer and, in this case, shall be applied to all the appliances of the same type. Markings ‘The various components of the electrical installations: appliances, conductors, cables, etc. shall be given material markings and rating plates giving information on their nature and the section to which they belong, All marking and labels shall be in English, clearly readable and indelible. Design Manager Technical Manager Design by | SCI ey | Hoang The Vinh Ngo Vu An Pham Van Cuu ewBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Llectro-Mechanical Equipment 6) @) 6) © ” ®) ) (10) Markings on diagrams shall be designed to make such diagrams easier to read and understand and to indicate the exact location of appliances and terminals which may have to be inspected, especially for troubleshooting purposes. ‘The material markings used must enable the corresponding components of the installation to be located rapidly and without ambiguity both on the diagram and in the actual installation, Markings shall be given on: a, the main installation centres such as the machine room, control room, outdoor substation, etc., b. items of the installation which form functional assemblies or subassemblies, such as parts of boards or cubicles allocated to a section, distribution boxes, cells, isolated switchgear and controlgear cabinets, main appliances (turbine, transformers, ete.), 4d. secondary appliances (relays, switchgear, controlgear, etc.), €. intermediate wiring terminals, f connections, & conductors, h. cables, Unless indicated to the contrary, the markings of the main installation centres shown on the diagrams do not need to be materialised in the actual installation The "installation components" must be very clearly identified by means of their complete composite marking with, in addition, an indication for identifying the section to which they belong. "Common items" must be identified by their functional markings with, in addition, a clear indication of their nature wherever possible. The main appliances shall be provided with their functional marking with indication of the section to which they belong and, where needed, the diagram sheet number on which they are fully represented. If necessary, they must also be provided with a rating plate clearly indicating their nature and exact function. This will be the case, for example, for contactors or circuit-breakers on the auxiliaries distribution board. S CI Design Manager | Technical Manager Design by — — Al Hoang The Vinh Ngo Vu An Pham Van Cuu MONBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment ay a2) a3) (4y cs) (6) A213. Devices which are fixed to panels and are back connected shall be identified both at the front and at the back of the panel. This will be the case, for example, for push buttons, switches, etc. Secondary appliances are always provided with their functional identification mark, In addition, they are identified as follows: a. with their position marker if they are fitted inside an installation ‘component and the main installation centre marker if they are installed alone, . with the sheet number of the diagram on which they are fully represented; Terminal strips are identified by means of the lower-case letter used on the diagrams for identifying the terminals in the strip. In a given installation component, terminal strip identification marks follow in order from top to bottom if they are horizontal, and from top to bottom and left to right if they are vertical; Intermediate wiring terminals are identified only by their order number on the terminal strip from 01 to 99. Each end of all cables is marked with an indelible label showing its number and an indication of the section to which the cable belongs. Each end of each conductor shall be provided wit a, the terminal number (appliance terminal, or intermediate wiring terminal) to which the conductor is connected, b, terminal tags atranged so that markings are easy to read. The choice of marking systems and marking fastening systems whether, dependent, independent or composite, shall be the subject of discussion between the Engineer and the Contractor. Design criteria In his dimensional design calculations, the Manufacturer shall allow for the most adverse conditions to be withstood by the structures, whether in normal operation or during manufacture, transport or erection. All parts shall be made with a sufficient safety coefficient to stand up to alternating forces, vibration, clectrodynamie forces induced by short-circuit currents under the most adverse conditions as well as to the corresponding temperature rise until tripping of protection systems. Design Manager | Technical Manager Design by SCI a a Hoang The Vinh Ngo Vu An Pham Van Cuu NON lsyfBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro- Mechanical and El. A22. A221. ay Q) @) @) 6) 6) oO A222. A22.2.1, a) Q) tro- Mechanical Equipment PRODUCTS, COMPONENTS AND SUB-ASSEMBLIES General The degree of protection of motors and enclosures (boards, cubicles, cabinets, tc.) within which electrical equipment is to be installed, shall be as follows: a. IP 31 for indoor LV equipment in air conditioned rooms; b, IP 44 for indoor equipment; ©. _ IP $5 for outdoor equipment. All mechanical and electrical equipment installed both indoors and outdoors shall be designed to resist the effects of atmospheric agents and specified climatic conditions in total safety. In view of the particularly severe climatic conditions, the equipment shall be subjected to "tropicalisation" treatment. All steel parts will be cadmium plated and passivated. Insulating parts will be made from anticreeper and antimould products, All electrical equipment components subject to normal or accidental wear shall be provided with removable parts for easy or economical replacement, if possible without requiring the total replacement of the components concemed. All assembly bolts and screws shall be locked after tightening. These bolts and screws shall be effectively protected from corrosion by cadmium plating, sherardisation or by any other process approved by the Engineer. ‘The ISO metric system shall be adopted for all threads. Corrosion protection General All electrical equipment shall be given factory protection against the corrosive effects of atmospheric agents and the sun's ultra-violet rays, During equipment handling operations both in the workshop and during transport and erection, the Contractor shall, insofar as possible, take all precautions to avoid damaging or blemishing the protective coatings already applied. ‘The Contractor shall be responsible for touching up work where necessary and, in extreme cases, may be required to replace cubicles or boards with damaged paintwork, iS Cc I Design Manager | Technical Manager Design by + Alf Hoang The Vink Ngo Vu An Pham Van Cuu eaten VAN weeBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment (3) Corrosion protection systems shall be selected considering the shipment, site storage and final use conditions. In particular, all equipment shall be given ‘marine protection, 22.2.2. Protection of cubicles and boards ' (2) Frames and outer partitions shall be made of galvanised steel plate protected by: a. An epoxy coating for frames, rear panels and end panels. b. Oven-fired glycerophthalic paint for front panels. (2) Internal partitions made of steel shall be treated in the same way or galvanised. Aluminium partitions may be left unprinted, A2.2.2.3. Protection of motors Machines shall be protected by a three-coat system, including two chromate primers and a polyurethane lacquer top coat. twme- Rotors shall be protected by an epoxy or polyurethane varnish; rating plates shall be made of stainless steel A22.24, Protection of transformers Both the inside and outside of metallic parts shall be corrosion protected. Prior to painting, the surfaces shall be treated either chemically or mechanically. The chemical treatment shall consist of dipping the pieces into a cleaning ‘mixture then, after rinsing, by dipping the pieces into bichromate of zinc. ‘The mechanical treatment shall consist of shot-blasting plus a coat of dichromate of zinc if the surface cannot be painted immediately after the shot blasting. Exterior surfaces shall be protected with one coat of chromate of zine primer and two coats of glycerophtalic paint. Interior surfaces shall be protected with one coat of chromate of \¢ primer. A223, Accessory electrical equipment Voltages to be used The low voltage, AC equipment shall operate at: a. 400 V three phase + 10% S CI Design Manager | Technical Manager Design by ALT Hoang The Vinh Ngo Vu An Pham Van CuBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechunical Equipment A22,3.2, a) @Q) @) @) A2.2,3.3, Q Q) @) A22,3.4, a) Q SCI b. 230 V single phase + 10% at frequency of 50 Hz. 2 Hz If another voltage is required for certain special items of equipment, the Contractor shall provide the necessary transformers. The low voltage DC equipment shall operate at rated voltages of 220 V and 48 V. All low voltage equipment shall be submitted to a minimum test voltage of 2000 V for a period of one minute (electronic equipment shall be disconnected during the test). Contactors All contactors shall conform to the IEC standards and recommendations. ‘Their nominal ratings shall be chosen 20% above the highest service currents. Under no circumstances shall the contactor operation in any way disturb or affect other relays installed on the same chassis. ‘Thermal or thermo-magnetic protection relays shall be installed on every phase; they shall be temperature compensated and shall include a single phase protection. In addition to the auxiliary contacts necessary for normal operation of the installation, each contactor shall be provided with a block of at least two extra instantaneous contacts (opening + closing). Circuit breakers ‘The installation of all AC and DC circuit-breakers shall comply with the IEC standards, ‘The cireuit-breakers shall be of the fast operating type with manual closing and automatic tripping. They shall be provided with thermo-magnetic relays on each line phase. Suitably calibrated high breaking capacity fuses or other limiting devices shall provide a back-up protection when the capacity of the circuit-breakers is insufficient to break short circuits, Protection and auxiliary relays The relays shall be of the ‘plug-in’ type. They shall be protected by a sealed cover and shall be mounted in a cubicle, on a relay chassis preferably made of aluminium or folded steel plate. The protection relays shall be carefully installed so that they shall not be affected by shocks or vibrations. The protection relays shall have their Design Manager | Technical Manager Design by a AD-8 1| Hoang The Vinh | Ngo Yuan Pham Van CauBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment adjustment devices on their front face and each relay shall be supplied with a i corresponding calibration curve. (3) The auxiliary relays shall be of the electro-magnetic coil type, AC supplied at 230 V or 48 V, DC supplied at 48 V or 110 V. (4) The making and breaking capacity of the contacts shall not be less than 10 A at 48 V, 2A at 230 V (resistive load and AC supply) and 5 A at 48 V, 0.6 A at 110 V (inductive load and DC supply). (5) The auxiliary relays must be able to function satisfactorily when the voltage variation is +10% and -20% of the rated supply voltage. 2.2.3.5. Change-over switches and push buttons (1) The change-over switches and push buttons shall be of the normal enclosure type, unless otherwise stated in the specifications. The minimum rated current shall be 10 A. (2) All isolating switches and push buttons shall have an engraved metal indicator ring describing their function, A2.2.3.6. Fault annunciators - signal lamps (1) Fault or operating mode signal boxes shall be of the multiple type consisting of a series of rectangular windows placed side by side both horizontally and vertically, Each box shall be fitted with one or several lamps and a translucent cover engraved with the corresponding function, (2) __ Each signal box assembly shall have at least two boxes in reserve. All external connections shall be of the screw terminal type. All signal lamps shall be able to withstand a voltage 15% greater than the rated voltage. (3) The fault signalling sequence shall be the following: a. When a fault occurs, the lamp flashes (signal stored) and the audible alarm starts up. b. The hom stops when the acknowledgment button is depressed. While the faults are persisted, if the other fault is coming , the horn/bell not to be block. When the ‘Reset’ button is depressed: i) if the fault persists, the fault signal lamp changes from a flashing light to remain permanently lit, S Cc I Design Manager | Technical Manager Design by a ALI Hoang The Vink Ngo Vu An Pham Van CuuBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3. Specification of Hydro-Mechanical and Electro-Mechanical Equipment Q) @) @ A22.3.8, a Q 6) @ ii) if the fault has disappeared, the signal lamp goes off (regardless of whether it was flashing or permanently lit). Terminal blocks to the different items of equipment, such as the indicators, recorders, relays, signal boxes, ete. shall be made with screwed fork-clip connections. In generél, the connection of the control and monitoring circui ‘The electrical boards, panels, cabinets, cubicles or chassis mountings shall have terminal blocks grouped in one or several rows, located in an easily accessible place. The terminal blocks for extemal circuits shall be located in the low voltage compartment of each board, panel, cabinet and cubicle. The terminal blocks shall be of the screw type and shall be made of insulating materials mounted on special steel supports. The parts of terminal blocks of different voltage ratings shall be separated by insulated compartments. The distance between any two adjacent terminals shall not be less than 6 mm. As far as possible terminals with isolator switches will be used. No more than one conductor shall be connected to any one terminal, the terminals being bridge connected for parallel connection. Each terminal block shall have approximately 10% spare terminals. For the purpose of connection the cable end shall be fitted with crimped terminals. Low voltage equipment cabinets, boards and panels All boards, panels, cabinets and cubicles shall be of the enclosed, dust and vermin-proof type. When installed outdoors or in humid places, they shall be designed to be weather-proof and be galvanised or zine-plated. In order to avoid oxidation caused by condensation, resistance heaters with thermostat shall be provided. The access doors shall be lockable from the outside although it shall always be possible to open them from the inside. ‘A corrosion resistant metal name plate, with an engraved description of the panel, shall be fixed to the top of the front face. The inscriptions shall be in English. The busbars shall be made of copper and marked with conventional colours. Copper cables shall be used for the internal wiring. All cable wires shall have end- hugs and shall be connected by one side only to the terminal block. Design Manager | Technical Manager Design by SCI mee | 5 Hoang The Vinh Ngo Vu An Pham Van Cu I cBasic Design Nam Mo 2 Hydropower Project Volume V- Part 3: Specification of Hydro-Mechanical and Llectro-Mechunical Equipment 6) © ” 2.2.3.9. @ Q) @) (4) So © a SCI Glands will be used for all cable inlets into the panels. The diameter of cable glands shall be determined as a function of the outside diameter of the cable. ‘The gland plate shall be drilled only at the time of installation of the gland. The front panels shall house the indicators, measuring instrument, recorder push buttons, control switches and the signal lamps and fault signal boxes. All equipment placed on the outside of the panels shall be of the built-in type, of standard dimensions, connected from behind, Motors Electric motors shall comply with the recommendations of TEC standards 60034-1 to 60034-9, 60072-1 and 60072-2. The motors shall be capable of starting under a voltage 10% below the rated voltage. Movor windings shall be Class B insulated. ‘The motors shall be designed (as per IEC recommendations 60034-1) a, For the gate: intermittent periodic duty time (83). b, For handling equipment: intermittent periodic duty time with electric braking ($5). ©. For pumps, fans, compressors and other equipment: continuous running duty type (S1). Vibration: The maximum values of RMS velocity at design operating speed shall not exceed the 1.8 mm/s criterion of VDI 2056 Group K. The following class will be chosen: a. N (normal) for machines up to a shaft height of 225 mm, b. _ R (reduced) for machines of shaft height between 225 and 315 mm and, by extension, above a shaft height of 315 mm. Ones installed, the uncoupled machine shall not be subjected to vibration in excess of these tolerances. ‘The permissible noise levels will be measured in dB(A). They shall be expressed in sound pressure and measured in accordance with French standard NF C 51-111 or Japanese standard JIS C 4210 (or equivalent). ‘Manufacture - Design: Design Manager Technical Manager Design by ADI Hoang The Vinh Ngo Vu An Pham Van CuuBasic Design Nam Mo 2 Hydropower Project Volume V-Part 3: Specification of Hydro-Mechanical and Electro-Mechanical Equipment @) SCI a. Frame: Motor frames and end plates shall be made of cast metal or of thick welded plate and shall be provided with: i) Lifting hooks for machines weighing more than 50 kg. ii) An ISO threaded terminal of 8 mm minimum diameter for connection to the earthing circuit; this terminal shall be located on a fastening lug, on the opposite side to the coupling or, if applicable, on the fastening plate. Provision shall be made for one or more condensation water drain holes in the bottom of the frame or bearings. b. Bearing blocks: Ball bearings with prestressing springs shall be used in preference to roller bearings. The bearings shall be guaranteed for 30 000 hours of operation without incident at the rated speed of the machine, Lubrication shall be preferably by grease, and shall not require grease replacement during the guaranteed period of operation. c. Cooling: ‘The motors shall be of the self-cooling type with shaft-mounted fan, The cooling air shall be directed towards the coupling side (fan mounted on the opposite side to the coupling). 4. Terminal box: The Contractor shall provide terminal boxes which shall be adapted to the types of cable powering the motor. The boxes shall have the same degree of protection as that of the motor. The terminals shall be clearly marked. One earthing terminal shall be provided. ec. Windings: Windings shall be made of annealed copper. Each motor will be provided with a corrosion free nameplate marked with the following motor characteristics: a, Name of manufacturer, b. Type, serial number and manufacturing number. Design Manager Technical Manager Design by A2-12 | Hoang The Vink NgoVudn | Pham Van Cuw