You are on page 1of 82

MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender

Gas Power Plant Projects 2011

Republic of Iraq
Ministry of Electricity

DIBIS 2xSGT5-PAC 2000E


Dual fuel + Heavy Fuel Oil

CHAPTER 4

GENERAL TECHNICAL REQUIREMENTS

TOTAL PAGES: 82
Including this page

Page 1 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

Table of Contents

DIBIS 2xSGT5-PAC 2000E, Dual Fuel + Heavy Error! Bookmark not defined.
4 GENERAL TECHNICAL REQUIREMENTS 6
4.1 Programmes and progress 6
4.1.1 Programme requirements 6
4.1.2 Design Schedule 6
4.1.3 Procurement and manufacturing schedule 6
4.1.4 Preliminary Construction Schedule 7
4.1.5 Construction Schedule 7
4.1.6 Commissioning Schedule 7
4.1.7 Progress reporting 7
4.2 Design and standardization 9
4.3 Drawings and documents 12
4.3.1 Drawings enclosed with the Specification 12
4.3.2 Schedule 13
4.3.3 Drawings and documents to be submitted by the Bidder 13
4.3.4 Drawings and documents to be submitted by the Contractor 13
4.3.5 Drawings and documents format 14
4.3.6 Drawings sheet numbers 15
4.3.7 Drawings and document revision number 15
4.3.8 Drawings and document revision status 15
4.3.9 Component identification 16
4.4 Operating and maintenance instructions 16
4.5 HAZOP studies 19
4.6 Materials and Workmanship 20
4.6.1 General 20
4.6.2 Allowable Stresses 22
4.6.3 Tests on Materials 24
4.6.4 Workmanship 26
4.7 Protection against Atmospheric Agents 29
Page 2 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
4.7.1 General 29
4.7.2 Metals 29
4.7.3 Bolts, Screws, Nuts, Washers 29
4.7.4 Fabrics, Cork, Paper, etc. 29
4.7.5 Adhesives 29
4.7.6 Electrical Materials and Equipment 30
4.8 Mechanical Details 30
4.8.1 General 30
4.8.2 Drums 30
4.8.3 Sheaves 30
4.8.4 Wire Ropes 30
4.8.5 Hooks and Blocks 30
4.8.6 Shaft and Bearings 30
4.8.7 Gears 31
4.8.8 Wheels 31
4.9 Piping, Valves and Threaded Fasteners 31
4.9.1 General 31
4.9.2 Pipes 32
4.9.3 Valves 32
4.9.4 Threaded Fasteners 33
4.10 Pumps 34

4.11 Electrical Equipment 35


4.11.1 General 35
4.11.2 Motor Control Centers, Distribution Boards, Panels, Boards, Cabinets and Local Control
Panels 36
4.11.3 Molded Case Circuit Breakers 39
4.11.4 Magnetic Contactors 39
4.11.5 Thermal Overload Relays 39
4.11.6 MV and LV Indoor Current and Potential Transformers 40
4.11.7 Terminal Blocks 40
4.11.8 Auxiliary and Time Delay Relays 40
4.11.9 Fuses 41
4.11.10 Indicating Lights 41
4.11.11 DC/DC Converter 42
4.11.12 Electrical Control Devices Manually Operated 42
4.11.13 Electric Motors 43

Page 3 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
4.11.14 Boards and Panels Wiring 44
4.11.15 Low Voltage, Control Cables and Accessories 44
4.12 Grounding Connections 49
4.13 Control, Protection, Signaling and Metering Equipment 49
4.13.1 General 49
4.13.2 Instruments 49
4.14 Treatment of Surfaces 51
4.14.1 General 51
4.14.2 Preparation of Surfaces 51
4.14.3 Paints and Painting Equipment 52
4.14.4 Application of Paint - General Standards 52
4.14.5 Zinc Plating 52
4.14.6 Colours 52
4.14.7 Inspection, Tests and Guarantees on Painting 53
4.14.8 Painting Schedule 53
4.15 Places of manufacture, testing and inspection 54
4.16 Training 54
4.16.1 General 55
4.16.2 Content of training 56
4.17 Spare Parts 56
4.18 Special tools and lifting device 57
4.19 Warranty engineer 57
4.20 Quality Control, Inspection and testing 57
4.20.1 General 57
4.20.2 Extent of work 58
4.20.3 Document submission 59
4.20.4 Inspection notification and right of access 60
4.20.5 Inspection and tests 60
4.20.6 Non-conformances 61
4.20.7 Quality control records, certificates and certificates of conformance 61
4.20.8 Specific tests and inspections 62
4.21 Meetings 62
4.21.1 Meetings during design phase 62
4.21.2 Meetings during construction phase 62
4.22 Construction control requirement 64
4.22.1 General 64
4.22.2 Project schedule 65
Page 4 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
4.22.3 Progress updated 65
4.22.4 Cost control 66
4.22.5 Guideline and instruction 66
4.22.6 Guideline and instruction 67
4.22 Construction inspection & monitoring program 68
4.23.1 General 68
4.23.2 Areas of inspection 68
4.23.3 Material deficiencies 69
4.23.4 Material receiving instruction 69
4.23.5 Material deficiency report 70
4.23.6 Storage yard inspection report 70
4.23.7 Contractor responsibility 71
4.23.8 Non-conformance report 71
4.23.9 Contractor responsibility 71
4.23.10 Disposition 71
4.23.11 Review approval 71
4.23.12 Non-conformance report log 71
4.23.13 Completed non-conformance reports 72
4.23.14 Stop work order 72
4.23.15 Construction checklist 72
4.24 Commissioning, Start-Up, and Tests On Completion 72
4.24.1 Plant startup program 72
4.24.2 Pre-commissioning 72
4.24.3 Commissioning 76
4.24.4 Environmental performance guarantee tests 81
4.24.5 Reliability test 81
4.24.6 Test records 82

Page 5 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
GENERAL TECHNICAL REQUIREMENTS

Programmes and progress

Programme requirements
All bidders shall submit an integrated project schedule in the format of a typical schedule in Primavera that
will be available with the bid document. During the contract negotiations the integrated schedule will be
finalized and approved by MoE. The Contractor will be fully responsible to implement the project per the
contract schedule barring any force majeure mandating time extension. The above approved schedule shall
be reviewed again and re-basined prior the completion of the drawing delivery milestone that is 91 days after
EPC Award. The major milestones like First Fire and COD for each unit shall not be subject to change at the
time of the re-baselining of the schedule.

The programmes supplied by the Contractor will be used by the MoE to monitor the overall progress of the
project. Primavera project management software is preferred for all programmes for the duration of the
Contract. The programmes supplied by the Contractor as part of this Project shall fully interrelate design,
procurement, manufacture, erection and commissioning activities and fully man-loaded. Key events shall be
clearly identified on all programmes and be integrated in to the program logic. The Contractor shall use the
existing WBS and coding structure from the Primavera Project Schedule. All activities in the schedule shall
be logically connected and the critical path(s) identified. Contractor will issue the Project Schedule that will
include the entire work scope for the project and define Work Breakdown Structure (WBS) to be used.
Contractor will prepare Level 3 schedule with planned complete date Engineering, Procurement,
Construction & Commissioning.

The approved programme shall be adhered to by the Contractor and shall not be changed except as agreed by
MoE. If at any time during the execution of the project it is found necessary to modify the approved
programmes, the Contractor shall inform the MoE and submit the modified programmes for its approval.
Any approval or changes to the approved programmes shall not constitute approval of an extension of the
guaranteed completion date, or any approval of claims for increases in the EPC price.

Design Schedule
The Contract Programme shall incorporate design activities that identify the sequence of work for the
project and submission of drawings, studies and reports etc. The Design Schedule shall be electronically
extracted from the Contract Programme and shall contain all major documents and drawings to be
submitted for review by the Owners Engineer, their submission dates and durations for review as specified
by the Owners Engineer, and shall meet the requirements of the Contractor and other contractors engaged
on the project.

Procurement and manufacturing schedule


The Contract Programme shall incorporate a Procurement and Manufacturing Schedule, which identifies as
a minimum:

a. Details of suborders and target dates for placing subcontracts

b. Any detailed design required within the manufacturing period

c. Long delivery items

d. Information to be supplied by Owners Engineer/Owner submission dates.

Page 6 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Procurement and Manufacturing Schedule shall be electronically extracted from the Contract
Programme and shall be in sufficient detail to enable the work to be adequately progressed. This schedule
shall meet the requirements of the Contractor and other contractors engaged on the project.

Preliminary Construction Schedule


The Contract Program shall incorporate a preliminary construction schedule, which should identify in
sufficient detail the Contractors intended construction strategy. The programme shall satisfy the following
criteria:

a. Contain full details of all civil/mechanical/electrical terminal point release requirements

b. Identify when services are required for commissioning purposes

c. Include an outline setting to work and commissioning schedule.

The Preliminary Construction Schedule shall be electronically extracted from the Contract Programme.

Construction Schedule
The Contract Programme shall incorporated a detailed level 3 Construction Schedule, expanding the detail
in the Preliminary Construction Schedule and be electronically extracted from the Contract Programme. In
addition to the detail outlined in 4.1.4, this schedule shall be in sufficient detail as agreed by the Owners
Engineer, to enable the work to be adequately progressed and monitored. This to include long duration
activities of over 30 days to be broken down into sub-tasks of no more than 30 days duration. This schedule
shall meet the requirements of the Contractor and other contractors engaged in the project.

Commissioning Schedule
During the progress of the works, the Contractor shall develop the outline setting to work and
commissioning schedule into detailed level 3 Commissioning Schedule, in sufficient detail to enable the
work to be adequately progressed. Activities of over two weeks duration are unacceptable and shall be
broken down into acceptable sub-tasks. This schedule shall be electronically extracted from the Contract
Programme and submitted to the Owners Engineer for approval 3 months prior the start of any
commissioning activities and shall be approved not later than 1 month prior to the start of any
commissioning activities. This schedule shall meet the requirements of the Contractor and other contractors
engaged on the project, and shall be integrated with the Contract Programme.

Progress reporting
The Contractor shall provide on weekly basis the following progress status on the project:

Manpower status with break up for the complete project including Engineering, Procurement,
Construction, Commissioning, indirects and directs;

Progress quantities for Excavation (CuM), concreting (CuM), Structural steel (MT), Piping (both
linear M and mm Dia.), Cable laying (M), Termination (nos).

Monthly progress reports shall be produced by the Contractor and submitted to the Employer from the
commencement of the Contract. The format is to be approved by MoE. They shall be submitted within one
week of the report cut-off date to be agreed during negotiations. The report shall address design,

Page 7 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
procurement, manufacturing, construction, setting to work and commissioning issues. The reports shall
include but not be limited to the following:

1. Executive summary.

2. Schedule of forecast and actual key events.

3. Three month look-ahead programme (extracted from the Contract Programme).

4. Progress to date in narrative format.

5. Areas of concern and details of corrective action being taken.

6. Actual resources against planned.

7. Updated S curve.

8. Contract programme updated to show progress achieved. Programme progress updates shall also be
provided in the form of a fully working Primavera .prx /.xer electronic file and in form of Project
Schedule electronic file as set forth in paragraph 4.1.1 which will allow analysis by MoE. In addition, an
Electronic print or plot file shall be provided to MoE. Whenever there is a conflict, the form of electronic
file shall prevail over that in print form.

9. Planning and consents.

10. Safety issues and industrial relations.

11. Colour photographs of progress in digital format. Each set shall comprise a total of 20 colour
photographs, individually marked with the date taken, a description of the subject and the direction of
view.

12. Contract financial status according to the herein listed parameters:

Term Abbreviation Description Formula


Budget At Completion BAC How much was originally No one formula exists.
planned for this project to BAC is derived by looking
cost at the total budgeted cost
for the project.
Planned Value PV (or BCWS) How much work should have Planned %
(also known cost of been completed at a point in CompleteXBAC
work schedule) time based on the plan.
(also Budgeted Cost of (Derived measuring where
Work Schedule) you had planned to be in
terms of work completed at a
point in the schedule)
Earned Value (also EV (BCWP) How much work was Actual % CompleteXBAC
known as Budgeted Cost actually completed at a point
of work Performed in time. Derived from
measuring where you
actually are in terms of work
completed at a point in the
schedule
Actual Cost (also known AC (or ACWP) The money spent at a point in Sum of all costs for the
as Actual Cost of work time given period of time
Performed)
Cost Variance CV The difference between what EV AC
we expected to spend and
what was actually spent at a
point in time
Page 8 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Schedule Variance SV The difference between EV PV PV EV
where we planned to be in
the schedule and where we
are in the schedule
Cost Performance Index CPI The rate at which the project EVAC
performance is meeting cost
expectation
Schedule Performance SPI The rate at which the project EVPC
Index performance is meeting
schedule expectation
Estimated At EAC Projecting the total cost at BACCPI
Completion completion based on project
performance at a point in
time
Estimated To ETC Projecting how much will be EAC AC
Completion spent on project, based on
past performance
Variance At Completion VAC The difference between what BAC - EAC
was budgeted and what will
actually be spent

The Contractor may be required to include additional schedules and charts considered necessary by MoE to
adequately monitor the Contract.

Hard copies of progress reports are to be issued to MoE and Employer in accordance with Drawings and
Documentation annexed to the Chapter 3. An electronic copy shall also be submitted to both MoE and the
Employer.

Following mobilization at site, the Contractors site office shall submit weekly progress reports to MoE in
accordance with Drawings and Documentation annexed to the Chapter 3. The report shall summarize site
activities, indicate numbers of the various classes of workmen employed on site, the plant and equipment on
site and record any areas of concern and details of corrective action being taken. Daily activity reports shall
also be provided summarizing the main activities to be undertaken each day, noting any special activities that
require witnessing, together with full particulars and details of all obstructions, modified or additional work,
incidents and the number of men employed in each of the several portions of the work in progress, in
accordance with Schedule with Drawings and Documentation annexed to the Chapter 3.

Access to the Contractors or subcontractors works shall be granted to MoE at any reasonable time for the
purposes of ascertaining progress. MoE shall also have access to the Contractors daily activity reports.

MoE may request the Contractor to provide additional reports when in its opinion they are warranted.

Where there is an agreement to pay by time and material rates, the Contractor shall keep records of labour,
materials and equipment. Such records shall be submitted daily and be valid only when signed by both
parties.

For work of a disputed or uncertain nature, sheets shall be signed daily by both parties as an agreed record of
work done. The sheets shall be annotated For record purposes only and shall not imply any commitment
concerning payment.

Design and standardization


The Works shall be designed to ensure satisfactory operation in which continuity of service is the first
consideration and to facilitate access, inspection, cleaning, repairs and replacements. All equipment supplied
shall be designed to ensure safe and satisfactory operation under the environmental conditions prevailing at
the Site, and under such variations of load and pressure as may be met with under working conditions. In
Page 9 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
doing so the Contractor shall be responsible for and shall carry out HAZOP studies or other studies deemed
necessary by MoE as part of the design process. The Works and all equipment and materials forming part of
this Contract shall comply in all respects with any relevant statutory regulations, by-laws or orders currently
in force where the Plant is to be erected. The EPC design work including drawings (in agreed CAD format) ,
specifications and calculations shall become the intellectual property of the Employer and may be used by
other parties at the Employers discretion towards design of other power Plants in Iraq.

Prior to the start of design the Contractor shall prepare a Design Basis Document for each engineering
discipline defining all design criteria, engineering methods, structural and foundation systems, material
standards, construction procedures, workmanship and quality control protocols, and installation sequence
plans that will be used for the design of the plant. This document will be reviewed and approved by the
Employer/Owners Engineer.

A detailed listing of the Codes and Standards is given in annex to Chapter 3. These codes and standards shall
form the primary basis for the balance of plant also. More information is provided below.

Codes and Standards for the Balance of Plant

The Supply of Equipment and Performance of the Work, object of present Contract, must conform to the
Laws and Regulations existing in the Republic of Iraq which shall be identified by the Contractor, in addition
to the particular prescriptions given here.

All materials and equipment to be incorporated in the works and fabrication of same, except as otherwise
provided, shall conform to the latest revision or edition of the Codes, Standards Design Manuals and
technical references listed below.

The Contractor is strongly encourage to supply all materials, designs, services, methods, and procedures for
the design and construction of the Works consistently in accordance and compliance with codes and
standards originating from a single national or international source, that is Exclusively American, or British,
or European, or ISO. Substitution or supplementing with codes and standards foreign to the primary
sources should only be invoked where required by local authorities, or where no comparable material or
standard exists from primary source. The intention is to avoid conflicting and incompatible requirements.

The Codes and standards to be adopted for the Balance of Plant have been indicated in Chapter 3 of the
present Specification.

The Contract shall submit two copies of the equivalent accepted standards in English or with English
translation, showing the correspondence with the Standards specified in the Technical Specifications.

If the Contractor, after the date of signature of the Contract, proposes other equivalent Standards and
Specifications and Standards of equivalent material, the Contractor shall state the exact nature of the change,
and shall submit complete Standards and Specifications and information and data on the material for the
approval of MoE. MoE reserves the right to reject such request. In addition such submittal shall be timely
and failure to do so, or purchase of any proposed equivalent materials prior the approval will be at
Contractors risk.

All documents such as drawings, descriptions, notices, letters, data, instructions, etc., shall be in English
language.

In the event of any conflict in standards, the hierarchy of standards shall be as follows, with the standards
occurring first in the list taking precedence over any standards later in the list:

1. Standards named in the Specification

2. International Standards

Page 10 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
3. Other standards approved by MoE.

The Contractor may offer Works which comply with international standards, or internationally recognized
codes or standards, which differ from those specified. However the Contractor may offer Works which
comply with the different standards or codes only if he is able to demonstrate to MoEs satisfaction that the
Works offered are equal or superior to that which would have resulted had the specified code or standard
been used. This substitution of codes or standards for those specified will only be acceptable if the
manufacturing organization in question has extensive experience with the alternative code or standard
offered. If requested to do so by MoE, the Contractor shall supply to MoE, at its own cost, two copies in
English of the relevant code or standard which he proposes to substitute for that specified.

The Contractor shall be responsible for ensuring that all standards used are current, the use of superseded or
obsolete standards is unacceptable. The ruling date for current standards are those in place at the time of
Contract signature.

The International System of Units (SI) shall be used in connection with this Contract and the provisions of
ISO 31 and ISO 1000. All materials, fittings, components, items of plant and equipment supplied for
incorporation in the Works shall be standardized accordingly. If, after making diligent enquiries, the
Contractor is unable to obtain an item standardized in SI units, written approval shall be obtained from MoE
to supply non-standard material.

The principal units shall be as follows:

Parameter Units Remarks


Pressure bar absolute All calculations relating to plant performance

bar gauge All pressure gauges

millibar Gauges below atmospheric pressure


Temperature C
Volume l (m) litre
Mass kg (t) (metric tonne)
Flow-mass kg/s (t/h)
Flow volume l/s (m/h)
Flow gas kg/s (Nm/h) (measured at 0C 1.013 bar a)
Rotational speed Rpm
Power kW
Enthalpy kJ/kg (MJ/Nm)
Vibration Mm (amplitude peak to peak)
Head m of H2O (mm Hg)
Heat rate kJ/kWh
Emission level Kg/m3
Alternative units indicated in brackets, may be used with the agreement of MoE.

SI units shall be used in all correspondence, documentation, calculations, drawings, measurements etc. If
reference has to be made to non-standard items, the SI units shall be quoted followed by the non-standard
units in brackets.

The Contractor shall standardize mechanical and electrical equipment as well as instrumentation.
Corresponding parts shall be made to gauge and shall be interchangeable wherever possible. When required
by the Engineer the Contractor shall prove this quality by actually interchanging the various parts.

Particular attention must be paid to internal and external access in order to facilitate inspection, cleaning and
maintenance. The Works shall be arranged such that each major item, plant, or group of minor plant items,

Page 11 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
can be safely isolated from all hazards for maintenance, if necessary, whilst the remainder of the plant
remains in service.

The design shall conform to the best current engineering practice. All plant shall be of the manufacturers
standard design, provided that this design is in general accordance with the Specification and shall use
components proven to be satisfactory by previous experience.

The design dimensions and materials of all parts shall be such that they will not suffer damage as a result of
stresses under the most severe service conditions. The materials used in the construction of the Plant shall be
of the highest quality and selected particularly to meet the duties required of them. The plant shall be
designed and constructed to minimize corrosion. Workmanship and general finish shall be of the highest
class throughout.

All equipment shall be designed to minimize the risk of fire and damage which may be caused in the event of
fire.

The equipment shall also be designed to prevent ingress of all vermin, accidental contact with electrical live
parts and minimize the ingress of dust and dirt. Power cables will be armoured.

The Contractor shall provide the services of an approved Classification Society or Insurance Inspection
Company subject to MoEs approval and which shall include:

a. the certification of designs and drawings and the checking of scantlings of the components of pressure
and vacuum containing parts

b. the certification of designs and drawings of lifting equipment and any other items of plant and
equipment which in the opinion of the Engineer requires insurance inspection

c. the inspection and certification that all such components and plant items are manufactured, constructed
and tested in accordance with the accepted standards

d. the inspection and certification of pressure or vacuum containing parts, lifting equipment, welding and
associated non-destructive testing of such welding, during erection and commissioning on Site.

All certificates shall be distributed in accordance with the requirements of this Specification.

Drawings and documents

Drawings enclosed with the Specification


A list of the drawings to be read in conjunction with the Contract requirements is given in Chapter 3. The
drawings issued by the Owners Engineer during the design phase of the Contract shall form part of the
contract documents and are intended to be descriptive of the character of the works and used in
conjunction with the requirements of the Contract document and shall in no way limit the responsibility of
the Contractor to supply all plant and equipment and services necessary to provide for a complete and
functional complex. Any omission from both drawings and the Contract documents or express reference to
any detail or work necessary and obviously intended shall not relieve the Contractor of its responsibility to
include that detail or work

The sizes of the buildings shown on the Bid Specification drawings are approximate, since the actual size
will depend on the size and shape of the plant, equipment and materials forming the Contractors Works and
the space required for installation, maintenance, lay down, storage, access, etc.

The drawings depicting Civil Works do not portray exact requirements but are intended to be an indication of
the type of work required.

Page 12 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
When measurements are affected by conditions already established, the Contractor shall take and be
responsible for field measurements notwithstanding any information given on the Bid Specification
Drawings.

Schedule
The following data are given in Chapter 3

Manufacturers technical particulars

Drawings and Documentation

Tests and Inspections

List of special tools and equipment

Drawings and documents to be submitted by the Bidder


The Bidder shall submit with each copy of its Bid a complete sets of drawings, catalogues, etc. which shall
serve to fully describe the scope of its Bid. These drawings shall include but not limited to, general and
dimensioned equipment arrangement drawings, narratives, sketches, material details, process system flow
diagrams, electrical one-line diagrams, and any other details required to completely describe the proposal
and enable evaluation by MoE.

The Bidder may also support their Bid with manufacturers catalogues where such catalogues illustrate
operational features that cannot easily be depicted on drawings or narrative text. System descriptions should
however be specific to the equipment offered and the wholesale use of generic catalogue is not acceptable.

Drawings and documents to be submitted by the Contractor


In order to ensure that SIEMENS's Functional Guarantees are met and that the plant BOP is designed to meet
the Turbine Generator requirements, it is obligation of the Contractor and its Architect Engineer (AE) to
submit to the Owner for Design Reviews all necessary documents (drawings, calculations notes, design
manuals, equipments specifications & data sheets, installation-commissioning-operation and maintenance
procedures) for the complete project construction, erection, start-up, commissioning and operation,
demonstrating that BOP equipment design will support Gas Turbine reliable long term operation and meet
the expected performance.

A list of the drawings and documents to be submitted by the Contractor during the Contract implementation
stage is specified in Chapter 3. The Contractor shall also submit any further drawings or documents as may
be reasonably required by MoE, during the design and construction of the Works. The Contractor shall
prepare and submit to MoE, review drawings (including dimensioned general arrangement, layout and
detailed design drawings), and documents (including schematics, Process and Instrumentation Diagrams
(P&IDs), data sheets, descriptions, plans and schedules) of all the plant and equipment specified in the
Specification. Drawings and documents already submitted by the Contractor and reviewed by MoE, and such
drawings and documents as shall be thereafter submitted by the Contractor and reviewed by MoE, shall not
be departed from without the written instructions of MoE.

Copies of each drawing, calculation and data shall be submitted in accordance with the programme given in
the Schedule in Schedule of Contract Drawings. If the Contractor requires early review of any drawing or
document to avoid delay in the delivery of the Contract Works, he shall advise MoE to such effect when
submitting the drawing or documents. The sequence of submission of items shall be such that all information
necessary for assessing each item is available at the time when received. In all cases, the drawings or
documents shall be submitted in sufficient time to permit modifications to be made if such are deemed
necessary by MoE without delaying the delivery of the Contract Works.

Page 13 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
As soon as practicable, and not later than 2 calendar weeks after receipt, MoE will advise the category of the
drawings as Reviewed or Reviewed as Noted , or Returned for Correction , as may be appropriate.
The categories Reviewed and Reviewed as Noted authorize the Contractor to proceed with manufacture
of the equipment covered by such drawings subject to the corrections, if any, indicated thereon. Where prints
of drawings have been Returned for Corrections, the Contractor shall make the necessary revisions on the
drawings and submit further copies for approval in the same procedure as for the original submission of
drawings.

Drawings shall be submitted for review at all stages of revision. The Contractor shall supply copies of each
drawing for revision as detailed in the Project Schedule, not later than 7 days after receipt of the comments.
Following review, additional copies shall be provided for use at Site as required by MoE.

All dimensions marked on drawings are to be considered correct, although measurements by scale may differ
there from. Detailed drawings reviewed by MoE are to be acted upon where they differ from the general
drawings.

Drawings showing the physical location of all devices and a plot plan showing the location of all equipment
shall be provided.

Drawings shall not be typical but shall actually represent the equipment provided. Drawings shall be
corrected to as built before final unit acceptance.

Approval of drawings shall not relieve the Contractor of any of its obligations under the Contract.

All legends and notes on drawings provided by the Contractor shall be in the English language. All drawings
shall be dimensioned in millimetres (or metres).

Drawings and documents format


Each drawing and document shall bear a unique drawing/document number. Individual items of equipment
forming a part of a drawing shall be clearly identified by means of tables or other approved methods.

Each drawing shall incorporate the following information:

a. Location

b. Drawing title (shall contain no abbreviations).

c. Original drawing sheet size i.e. A0, A1, A2, A3 or A4

d. Drawing status

e. Drawing number with provision for sheet and revision suffixes

f. Drawing date

g. Identity of persons carrying out, checking and approval

h. Scale or not to scale

i. Project/contract number

j. Revision

k. North point on geographically related drawings

The Owners information shall be in the form of the Owners Drawing Information Box. This box shall be
located at the bottom right-hand corner of the drawing.

Page 14 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Documents submitted for review or approval shall incorporate the following information:

1i. Document title (shall contain no abbreviations)

ii. Document status

iii. Document number

iv. Identity of person carrying out the preparation, checking and approval

v. Project/Contract number

vi. Revision

Drawings sheet numbers


All drawings shall have a three digit sheet number.

Where only one sheet exists the sheet number shall be 00, where more than one sheet exists the sheets shall
be numbered from 01 to 99 accordingly.

Drawings and document revision number


All drawings and documents shall have a two digit revision number and all changes shall be clearly indicated
by the addition of the following: appropriate revision number, revision date; identity of persons carrying out
drafting, checking and approval; concise details of the modification.

The change of drawing status shall result in a revision increase of one, whether there are changes to the
drawing or not.

Drawings and document revision status


Status definitions shall be used on all drawings and documents. The status shall not be part of the drawing or
document title. The definitions are as follows:

a. For approval

b. For review

c. For information (for non-project/contract drawings)

d. For bid purposes

e. For construction (includes manufacturing)

f. As built and records

All revisions of drawings shall be submitted in the following formats as detailed below:

i. A contract drawing list giving the Contract number, manufacturers number, sheet number, revision
and title of each drawing

ii. Paper prints of each drawing - full size

iii. Paper prints of each drawing - A3 size

iv. AutoCAD ACAD 2007 drawing file

v. Drawings in PDF format

Page 15 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Contract drawing list shall be submitted by the Contractor for review by MoE who will indicate thereon
the Employers requirements. On completion of commissioning, all drawings shall be updated and marked
as built. These shall be supplied as final record drawings.

The AutoCAD ACAD 2007 drawing files referred to above shall be imported and exported on media such as
Digital Linear Type (DLT) or CD. Each media shall be clearly labelled and accompanied by a transmittal
sheet showing all file details.

Where the file format is restricted, the transmittal sheet shall clearly show how filenames relate to drawing
numbers

Construction & Commissioning procedures will be submitted 6 months prior to start of site activities

Component identification
The Contractor shall provide a technical Specification to explain the proposed system of identification for
equipment and all other item included in the BOP.

Operating and maintenance instructions


The Contractor shall supply complete and detailed Operating and Maintenance manuals in English covering
the operation and maintenance of the plant and equipment as required by the Contract.

The contents of the operating and maintenance instructions, together with all drawings, illustrations and
diagrams shall refer specifically to the plant and equipment being supplied under the Contract, and shall be
specially prepared where necessary. General instructions referring to a range of equipment is not acceptable.

Operating instructions shall detail all integrated plant normal pre-start checks, starting up, running and
shutting down procedures, for the various modes of operation of the plant from cold, warm or hot conditions,
emergency operating procedures and any precautions recommended to prevent plant deterioration during
periods of non-operation. Operating instructions shall cover local/remote and manual modes of operation and
shall also include action on receipt of alarms.

The Contractor shall prepare a comprehensive commissioning schedule for each plant item and check lists to
record the completion of these activities. Copies of all settings and/or calibrations of instruments and
controls, pressure switches, trips and alarm settings confirmed and recorded in the commissioning schedules
shall be forwarded to be included in the Operating Instructions.

[Five] sets of draft copies of the commissioning manuals and operational and maintenance manuals shall be
submitted to MoE for review

[6] Months before commissioning commence. They shall be submitted as complete texts. In the event that
amendments or alterations to the draft manuals are required, the Contractor shall submit revisions for review
without delay, in any case within 21 days so that the final documents can be supplied within the date
specified.

[Twelve] hard copies and [five] soft copies of the final documents shall be submitted within 4 months after
the Taking over Certificate.

Page 16 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The whole of the operating and maintenance instructions shall be securely bound in approved covers and
provided with an index for easy reference.

The O&M manuals shall be provided in paper hard copy and in electronic copy on CDROM to a standard
document reader format (i.e. Adobe Acrobat Reader).

The instruction manuals shall conform to the following format:

a. Index

The index system shall provide rapid and easy access to particular subjects, drawings and illustrations.
It should include a master index and a sub-index to each main section of the manual.

b. Description

This section shall include basic data on the Plant.

i. Descriptions of the Plant both for individual items and for the systems into which items are
assembled.

ii. Drawings sufficient for the understanding of descriptions.

iii. Flow sheets or single line and block diagrams which explain the functioning and logic of the
system. Where related systems are shown on composite diagrams, individual systems shall be
identified by colour, or coding as agreed

iv. Schedules which assemble references to items of a like kind, e.g. valve schedules, piping schedule,
operational limit schedule, switchboard outline schedule, etc.

v. Data sheets which assemble in a concise format relevant technical details of a plant item or system.
The purpose of a data sheet is to provide quick reference to the essential facts omitting all
reference to general descriptions, operating or maintaining principles and instructions

c. Operation

This section shall include basic step-by-step instructions on how to operate the Plant both with
regard to individual items and to systems under all patterns of normal and abnormal conditions. The
instructions shall include reference to the applicable operation limits.

Precautions and warnings relative to the safety of life and equipment shall be included where
relevant.

d. Maintenance

This section shall include the following:

i. Build-up and assembly of systems and description of plant items.

ii. Schedule of equipment giving manufacturers name, the make/model No/catalogue No and parts
list including any special spares ordering instructions. Spare parts catalogues shall be provided for
the various items of equipment supplied.

iii. Routine maintenance schedule.

iv. Preventative maintenance and schedule of inspections.

v. Details necessary to carry out overhauls.

vi. Details necessary to locate and rectify faults.


Page 17 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
vii. Details necessary to set up, test and adjust plant systems and plant items. To include as a minimum,
fuel systems, carnage, ventilation, fire protection, water treatment plant and compressed air
equipment.

viii. Spares schedule.

ix. Schedule of recommended lubricants.

x. Sectional drawings of major items of plant, steam turbine, air cooled condensers, pumps, valves,
etc with dismantling instructions.

xi. As built copies of all relevant drawings corrected as necessary to incorporate any late
modifications.

xii. Plant layout drawing.

xiii. Schematic diagrams and general arrangement drawings of as-built control panels.

xiv. Wiring and cable diagrams.

xv. Plant equipment and performance curves.

xvi. Lifting gear register.

The final records shall include the construction and pre-commissioning data dossier with signed record
sheets.

e. Spare parts

This section shall comprise the critical, operational and optional spares as required by the Owner and
the spares as recommended by the Bidder. Details and full ordering procedures for each item of main
plant, auxiliary plant, electrical and C&I equipment and vendor equipment and shall include:

i. Spare part lists together with referenced sectional drawings from which the manufacturers
descriptive name and part number should be clearly identified for ordering purposes.

ii. Clear details of spare part suppliers address, spare part ordering procedure and including all
appropriate plan item reference numbers including serial numbers, type reference numbers,
original order numbers, etc. as required for the immediate and correct supply of spare parts from
various original plant suppliers.

In this context the term Suppliers Address means the sub-vendor or original equipment manufacturer.
It will not be acceptable for the Contractor to nominate himself as the supplier of a spare part unless he
manufactures the particular equipment, or it is manufactured by a third party in accordance with the
Contractors own manufacturing drawings.

iii. A list of spares for each type of operational/overhaul/inspection shall be provided.

Note: where spare parts are not available and full item replacement is necessary this fact is to be advised
and the appropriate ordering details provided as defined above.

For spares that are available from a multitude of sources (e.g. seals, O rings, gaskets, nuts, bolts, etc
the Contractor shall supply details of the sizes, standards and materials used. Details shall be provided
of any special storage requirements or limitations on storage life for spare parts.

f. Plant preservation schedule and methods

Page 18 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
This section shall cover the procedures for shutting down plant. Preservation during hibernation and re-
starting of plant.

g. Manual production

Accepted abbreviations of units of measurement are permitted in the text and illustrations. A list of the
abbreviations the Contractor proposes to use in the text and schedules is to be approved before work
begins on the manuals. As a guide it may be taken that abbreviations of terms will be permitted only
where they are in common use and readily understood, e.g. AC, DC, OCGT.

Drawings and diagrams shall, wherever practicable, be reduced to a convenient size, e.g. A3, and bound
into the manual. The reduced size drawings and diagrams shall be completely legible and suitable for
reproduction. Drawings which are referred to several times in the text shall be either of the fold out
type or visible when referring to other parts of a manual or be repeated as necessary. Throw-clear
drawings are to be included at the back of the relevant subsections, and their locations noted in the
Section drawing index.

Detailed engineering drawings necessary for maintenance and mentioned in the text but not included in
the manual because of size reduction difficulties, should nevertheless be listed in the drawing index.
The words NOT INCLUDED must be entered against them. Drawings are to be identified at the
bottom right corner by title and number.

Black on white line drawings should be used wherever possible, using line shading, and cross hatching
as necessary for clarity. Multi-colour and half-tone drawings using shading techniques, e.g. air brush,
should only be used in preference to line drawings where the additional information conveyed justifies
the effort and cost. Isometric and perspective illustrations are preferred to engineering (orthographic)
drawings, although engineering drawings may be included if they are more suitable due to the size and
complexity of a particular item of equipment. Where engineering drawings are used, clarify of detail
necessary to support the text shall be retained and in addition all irrelevant information such as
unnecessary dimensions, manufacturing information, borders, centre lines, etc should be removed. All
drawings shall be clearly marked by legend.

The manuals shall be produced as a book or books, with page size international A4, bound into strong
durable covers inscribed upon the front generally in the form of the title page to the Specification,
except that the references to the contents will be replaced by Operation and Maintenance Instructions.
Contractors standard pattern covers may be used, subject to the Owner Engineers approval.

The name of the main Contractor but not that of any subcontractor may also be inscribed upon the cover
after the description of the Plant.

The name of the Employer, the title of the project and Contract number followed by a brief description
of the Plant (e.g. water treatment plant, etc) shall be inscribed upon the spine of the cover. If the text is
bulky it shall be divided into conveniently sized volumes, and each shall be marked with the appropriate
volume number.

HAZOP studies
The design of the plant shall take into account good engineering practice with an emphasis on safe and
efficient operation and maintenance practices. The Contractor shall perform hazard and operability (HAZOP)
studies to demonstrate to the Owner and the Engineer that where possible all risks concerning safe and
efficient construction, operation and maintenance have been identified and solutions implemented to
eliminate such risks.

In the event that the HAZOP studies identify residual risks which cannot be avoided, the Contractor shall
incorporate measures in the design, implementation and project documentation (O&M Manuals) to ensure

Page 19 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
that the effects of the risk is mitigated and the likely effects on the operating personnel, the environment etc
are minimized. The Employer/Owners Engineer shall be provided the opportunity to participate in the
HAZOP reviews.

Materials and Workmanship

General
The material to be used under this Contract shall be new and without defects.
It shall ensure efficient service and life to each part of the machinery.
In particular, material shall not be of inferior quality to that specified below or stated in the Contract
Documents or specified in the Standards.

Material Standard Quality

Gray cast iron ASTM A 48 Class 35

Ductile cast iron ASTM A 536 Grade 60-40

Cast Carbon steel ASTM A 27 Grade 65-35 or 70-36

Cast alloy steel ASTM A 148 Grade 80-40

Corrosion resistant cast steel ASTM A 743 Grade CA-15

Forged steel for gears ASTM A 291 Class 1

Cold finished steel for shafts ASTM A 108 Grade 1022

Forged steel for shafts, trunnions, etc. ASTM A 470 Class 2


ASTM A 668 Class C
Wrought steel wheels and sheaves ASTM A 504 Class A

Forged alloy steel for general use ASTM A 668 Class G

Structural steel sections and plates ASTM A 36


Steel plates for low and ASTM A 283 Grade D
intermediate stresses ASTM A 516 Grade 60, 65, 70
Steel plates for high stresses ASTM A 225 Grade B
ASTM A 537 Class 1
Alloy steel for springs ASTM A 689
Corrosion resistant steel plates ASTM A 240 Type 304 or 410
Steel bolts and nuts (not submerged) ASTM A 307 Grade B
High strength steel, bolts nuts and ASTM A 325 Type 3 (to be
washers galvanized)
Corrosion resistant forged steel for ASTM A 276 Type 304, 410, 420
sections bolts and nuts
Welding rods for:
corrosion resistant steel According to AWS Standard
carbon steel According to AWS Standard
Steel piping ASTM A 53 Type S or E
Page 20 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Pipe fittings ASTM A 181 Class 70
ASTM 105-80
Galvanisation for:
steel piping ASTM A 53
section and plates ASTM A 123
bolts and nuts ASTM A 153
Cast bronze ASTM B 584 Alloy C 867 or Alloy C
937
Base metal for self-lubricated bearings and ASTM B22 Alloy C 90500 or Alloy C
bushes 86300
ASTM B 584 Alloy C 86200
Bronze for bearings, bushes, thrust shoes, etc. ASTM B 103 Alloy C 53200
White metal for bearings ASTM B 23 Alloy No. 3
Bronze for gears ASTM B 148 Alloy 955
Brass for bolts and nuts ASTM B 21 Alloy 485
Copper piping ASTM B 42 No. 102
Copper tubing for grease lubrication ASTM B 751
Copper alloy tubes for heat ASTM B 111 Alloy 687
exchangers
Chromium electroplating for pins ASTM B 177 Condition A or B
Gaskets for pipes and fittings ASTM A 564
Synthetic rubber for seals:
min. tensile strength
ASTM D 412 21 MPa
min. tensile strength after oxygen
bomb ageing (48 hr, 70C, 210
daN/cm2) in percent of tensile
strength before ageing
ASTM D 572 80 %
min. elongation at break
ASTM D 412 450 %
min. Shore hardness
ASTM D 2240 6070
specific density
1.15 0.3
max. water absorption (2 days at 70 C)
6 %
max. compression set (constant deflection)
in percent of original deflection 30 %
ASTM D 395
Method B
ACSR conductors ASTM B232
Electrolytic copper 99.9% min. purity
Aluminum for stranded conductors ASTM B-531-78 N 16 and H 26
Bronze for stranded conductors Minimum breaking load 500 MPa
Porcelain insulators IEC 75
Zinc coating ASTM A-123/153

Page 21 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Aluminum shims, plates and sheets ASTM B 209
Reinforcing Steel for concrete ASTM A615 Grade 60 Epoxy Coated
The materials not expressly specified shall conform to the most recently published ASTM Standards
regarding the class or type of those materials.
In case materials adopted are classified according to other material specifications, the Contractor shall submit
the list of equivalence of adopted materials to ASTM Standards.

Allowable Stresses
This subparagraph gives direction on equipment calculations; these directions shall be applied unless
different prescriptions are given in the following chapters or unless superseded by more stringent
requirements of plant equipment manufacturers.
The design dimensions and materials of all works and equipment shall be such that the stresses to which they
may be subjected shall not render them liable to distortion or damage under the most adverse service
conditions. Mechanisms shall be so constructed as to avoid sticking due to rust or corrosion. When required
for approval, stress calculation shall be submitted with all the indications necessary for a correct checking,
such as:
- materials adopted and reference Standards
- allowable stresses
- external loads calculation and stress calculation procedure, indicating the meaning and value
of each calculation coefficient
Above prescription is also applicable when the calculation is carried out by means of computer programs.
Calculation methods different from those herein specified can be used, subject to the following conditions:
- such methods shall be in accordance with Standards approved for the purpose of stress
calculation before signing the Contract;
- all the conditions stated by these Standards and relevant to the design, fabrication and
testing, when heavier than those specified by the present Contract, shall be complied with;
- the utilisation of these Standards shall not involve any restriction to the operating conditions
prescribed by this Contract.
The following design, fabrication and testing conditions shall be considered: the materials adopted; the
welded joint efficiencies; the forging and casting methods; the prescribed overthicknesses; the heat
treatments; the dimensional tolerances; the qualification of the fabrication procedures and operators; the
procedures for inspections and tests; etc.
Welded joint efficiencies to be adopted in the calculations shall be those prescribed by ASME Section VIII
PART UW, unless otherwise specified.
Double vee T welds and double-vee-corner welds joint efficiency shall be 0.8 if fully radiographed, 0.7 if
spot radiographed and 0.55 if not examined.
The loads to be considered in the stress calculations are:
a. Dead loads, including the weight of the water;
b. Load due to internal pressure or hydrostatic load;
c. Hydrodynamic load;
d. Load due to the wind acting on the installation area according to the prescriptions of these Technical
Specifications and, if not indicated, according to the prescriptions of approved local national Standards;
e. Earthquake load; See Chapter 10 Civil Works for design criteria.
f. Load due to driving and resisting forces, including acceleration and friction forces (the value of
friction coefficient, when not specified in the Technical Specifications, shall be taken according to the
best standard practice and shall be approved by MoE);
g. Load due to the temperature variations indicated in the Technical Specifications or to be agreed upon
with MoE;
h. Load due to support settings;
Page 22 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
i. Load due to support substructure deformations;
j. Load due to centrifugal forces;
k. Electromagnetic forces in normal operating condition and during fault conditions;
l. Load due to dimensional tolerances (values of these tolerances shall be those prescribed in the
manufacturing drawings);
m. Test loads;
n. Load due to equipment handling during transportation and erection;
o. Other normal and exceptional loads, when indicated in the Technical Specifications and/or strictly
depending on the equipment and its mode of operation.
The calculations to carry out are the following:
- calculation with maximum load;
- calculation with exceptional load;
- calculation with test load;
- elastic stability analysis, when required by the slenderness ratio and the type of load;
- other special analysis, when required in the Technical Specifications.

Maximum Load
As maximum load shall be considered the most critical combination of the following loads, referring to the
above mentioned items: a, b, c, d, f, g, j, k, l and o; the relevant values being calculated according to the
indications of the Technical Specifications. The wind effect to be considered for that calculation shall be half
the maximum prescribed.
In case no indications are given in the Technical Specifications, the loads to be assumed are the maximum
normal values calculated considering the rated operating conditions.
Exceptional Load
As exceptional load, shall be considered the most critical combination, even if improbable, of the following
loads: a, b, c, d, e, f, g, h, i, j, k, l and o; the relevant values being the maximum absolute values or the most
unfavourable for the purpose of calculation. Load h shall be considered in the calculation when required in
the Technical Specifications. When necessary, the equipment shall be calculated for the load n, limiting the
maximum deflections and/or the stresses; for the purpose of stress calculation this load shall be considered as
exceptional.
When necessary, in order to guarantee that interferences or bad functioning due to deformations do not occur
among the various parts of the equipment, a calculation shall be carried out considering that the maximum
allowable strains shall be such that, at maximum load, the good functioning of equipment and, at exceptional
load, no permanent damages are guaranteed.
For all rotating parts it shall be guaranteed that any natural flexural critical frequency is excluded in the
range 0.7 to 1.3 times the rated frequency and that any of the first and second order torsional critical
frequency has a value at least 30% different from any of the first and second order exciting frequency.
Dimensions of anchor beams, basements and any other parts to be supported or embedded in the concrete
shall be such that the max. compressive strength of the concrete shall not exceed 6 MPa, the max. shear
strength 1.4 MPa and the max. bond 0.7 MPa. The maximum load condition can take place with static or
variable loads according to the operating conditions and/or as specified in the Technical Specifications.
The stress T to be compared with the allowable one shall be calculated with the following equation:
T2 = T21 + T22 T1 x T2
where T1 and T2 are the main biaxial stresses.
The allowable stress shall not exceed the minor of the two values indicated in the following table for
each material and load type, where:
Y.P. = minimum yield point according to the relevant Standard
U.S. = minimum ultimate tensile strength according to the relevant Standard

Page 23 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Moreover, in case of impulsive load, the allowable stress shall not exceed 75% of the limits stated for the
maximum variable load, and for welded joint calculation the allowable stress shall also be multiplied by the
welded joint efficiency.
When secondary stresses due to the presence of reinforcing elements are to be considered, the allowable
stress, only in the points where such secondary stresses are taken into account, can be multiplied by 1.25.

Allowable Stresses Table


Max. Static Max. Exceptional Test Load
Load Variable Load
Load
Rolled and forged steel 0.55 Y.P. 0.37 Y.P. O.67 Y.P. 0.80 Y.P.
0.36 U.S. 0.24 U.S. 0.44 U.S. 0.52 U.S.
Cast Steel 0.44 Y.P. 0.29 Y.P. 0.54 Y.P. 0.64 Y.P.
0.28 U.S. 0.18 U.S. 0.35 U.S. 0.40 U.S.
Cast Iron 0.08 U.S. not allowed 0.10 U.S. 0.10 U.S.
tension 50 MPa not allowed 70 MPa 70 MPa
compression
Nodular Cast Iron 0.25 Y.P. not allowed 0.30 U.S. 0.36 U.S.
Bronze and self lubricated 0.17 Y.P. 0.17 Y.P. 0.22 Y.P. 0.25 Y.P.
material
Other Materials 0.36 Y.P. 0.24 Y.P. 0.44 Y.P. 0.52 Y.P.
0.22 U.S. 0.14 U.S. 0.27 Y.P. 0.32 U.S.
Elastic stability Analysis Minimum Safety Factor = 2

Tests on Materials
Non-Destructive Testing
Unless otherwise specified in the Technical Specifications, all non-destructive testing shall be carried out in
accordance with the latest edition of the following standards:
Castings
Radiographic examination:
ASTM E 446: minimum quality level 2 except for category A for which the minimum quality level shall be 3
ASTM E 186: quality levels as above
ASTM E 280: quality levels as above
Ultrasonic examination:
ASTM A 609: minimum quality level 2
Magnetic particle examination:
ASTM E 125: minimum quality levels: type I degree 0, other types degree 1
Dye penetrant examination:
ASTM E 165: evaluation to be agreed upon at the inspection and the acceptability will be subject to
agreement between MoE and the Contractor.
Forgings
Ultrasonic examination:
ASTM A 388: acceptability of any recordable indication shall be at MoE's judgment.
Magnetic particle examination:

Page 24 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
ASTM A 275: evaluation to be agreed upon at the inspection and the acceptability will be subject to
agreement between MoE and the Contractor.
Plates
Ultrasonic examination:
ASTM A 435
Welding
The tests that shall be carried out are those indicated in the Technical Specifications. If no indication is given,
the welds shall be tested according to the joint efficiency adopted in the calculations, following the
indications of ASME Section VIII Table UW-12. All welded joints assuring tightness shall be inspected or
tested by magnetic particle or dye penetrant. The Contractor shall indicate in the Fabrication and Installation
Drawings the type of non-destructive testing to be conducted.
The following prescriptions shall apply:
Radiographic Examination
According to ASME Section VIII par. UW-51 and for spot examination according to ASME Section VIII par.
UW-52.
Ultrasonic Examination
According to ASME Section VIII Appendix U. The ultrasonic examination will be considered equivalent to
the radiographic examination for the purpose of the weld efficiency factor determination, provided that the
following conditions are met:
all welds with indications exceeding 50% of the reference level shall be radiographed
following the prescriptions of ASME Section VIII par. UW-51; not considering the above radiographs,
10% of the welds carried out in the workshop and 20% of the welds carried out at Site shall be
radiographed.
Welds shall be divided into groups, according to the welding procedure and position of the
welds, and in agreement with MoE. In any case, welds carried out on different materials and/or by
different welders or welding machines and/or with electrodes of different quality shall not be considered
as pertaining to the same group.
The influence of thicknesses, castings and weld positions on the grouping shall be agreed with MoE. MoE
will choose the welds and/or the groups on which the radiographic examination shall be carried out. Should a
single unacceptable defect be found out, the whole group shall be radiographed, without considering these
radiographs as included in the above percentages.
Crossing point welds shall be 100% radiographed; also these radiographs are not included in the above
percentages. All welds to be radiographically examined will be countermarked with identification marks
appearing in the radiographic film and the marks shall not be removed before the approval of the relevant
weld has been given by MoE. The Contractor shall submit to MoE the radiographic film of all welds to be
approved, together with a localisation map of the relevant identification marks. All radiographic films shall
become the property of the Employer. Welds performed on automatic resistance butt-welding machine shall
undergo an indirect control providing sampling pieces. For each piece, mechanical tests and other tests
according to Contractor's practice shall be performed on the welding. In case one welding proves to be
defective, the adjacent welds shall be cut out and tested. All defects detected by inspection shall be fully
corrected and inspected again until the correction has been approved by MoE.

Materials Mechanical Tests and Chemical Composition


All principal materials, such as plates and sections subject to intermediate and high stresses, main castings
and forgings, shall be subject to the mechanical tests prescribed by the relevant Standards. Where no
definitive specifications are given, test pieces shall be obtained as required by the Main Owners Engineer.
Mill test certificates for chemical composition of the material shall be submitted. Test specimens and sample
shall be plainly marked to indicate the material they represent and, if required, shall be properly boxed and
prepared for shipment.

Test Certificates and Reports


a. General
Page 25 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Contractor shall carry out all tests as specified and shall record all test results in a satisfactory manner.
Concerning tests, some of them shall be witnessed by the Employer together with MoE.
b. Certificates
The Contractor shall furnish copies, as specified, of all mill certificates, material test certificates and welding
rods certificates. The test certificates shall be suitably identified with the component parts for which the
materials are to be used and shall be prepared in such a way that it can easily be determined, if the applicable
specifications or standards have been complied with.

Workmanship
General
The materials shall be accurately finished and shall be in accordance with the highest current technical
Standards. In particular, homologous parts shall be interchangeable with each other.

Castings
The Contractor shall advise MoE of the schedule for the casting of the pieces for which the inspection of the
blank is required. MoE will inspect these items after casting, before any repair work. Castings requiring
welding repairs and castings involving welding fabrication shall be stress-relieved unless otherwise
permitted by MoE. No welding shall be done after final heat treatment without the written approval of MoE.
Weld repairs shall be inspected or tested by radiograph, magnetic particle or dye-penetrant as considered
appropriate by Main Contractors Representative. The casting may be refused if the removal of metal
increases the computed unit stresses by more than 30% of that allowed prior to the defect. In any case, a
large number of defects may cause the refusal of the casting if, in the opinion of MoE, its strength will be
affected by the defects.
MoE may require the radiographic examination of the main castings and/or other testing methods. The
Standards shall be followed both in testing methods and in the result interpretation.

Forgings
The structure of forgings shall be homogeneous and free from excessive non-metallic inclusions. Excessive
concentration of impurities or separation of alloying elements at critical points will be cause for rejection.
Any welding repair shall be approved by Owners Engineer and, if approved, shall be carried out in
accordance with ASME Code Section VIII. All main forgings shall be ultrasonically tested. All forgings shall
be annealed or normalised as a final heat treatment.

Plates and Steel Sections


Plates and steel sections must be perfectly straight, with smooth surfaces. If straightening is necessary,
hammering must be avoided. After the cutting of sheets and steel sections, the edges must be left sharp, clean
and without burrs. High thickness plates may be flame cut, provided that the material is not damaged and
that the edges of the cut shall be ground clean or machined. Plates shall be cold rolled; in case of correction
of the bending, heavy blows shall be avoided. Should hot-rolling be necessary, special care shall be taken to
avoid overheating. All plates with thickness higher than 25 mm shall be ultrasonically examined before
machining. The steel plates for shells of parts under pressure must not only meet corresponding requirements
for chemical composition, tensile and bending properties, hardness and other tests in ASTM Standards, but
also the specifications for brittleness as may be required for the particular material by the ASME Code for
Unfired Pressure Vessels. All tests shall be performed before the start of fabrication and the results submitted
for approval to MoE or its authorized representative.

Welding
General
Welding, whether manual or automatic, shall be carried out with electric arc. The welding procedures must
be such as to ensure full penetration joints, free of internal and external defects. The edges to be welded must
be prepared accurately and have smooth clean surfaces. The Contractor shall indicate in the drawings the
field and shop welding joints preparation. Edges of plates of different thickness shall be tapered according to
Standards. Welding Procedure Specifications (WPS) shall be submitted for approval to MoE. In the
construction, welding procedures and welders qualification shall be in accordance with the ASME Code for
Page 26 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Unfired Pressure Vessels and relevant certificates shall be made available to MoE upon request. Test
procedure and result interpretation shall be in accordance with the ASME Standards.
Laminations
Any plate in which lamination has been discovered after cutting shall be rejected, unless the lamination
portion of plate is local and can be cut out and replaced by welding of a new sound plate in the cut-out area.
In such cases, the approval of MoE for repairs will be required.
Welding Equipment at Site
The welding equipment at Site shall include all devices necessary to avoid arc extinguishing and to ensure a
steady supply voltage within one tenth of five percent. Voltage shall not be higher than 80 V.
Electrodes
The Contractor shall indicate in all detail drawings the type and size of electrode he proposes to use for shop
and/or field welding. The electrodes shall be shipped suitably packed in weather-proof metal boxes and kept
inside their box up to their use. Should any box be damaged, the electrodes shall be replaced. The electrodes
to be used shall be maintained in a drying oven at a temperature of about 90C. Electrodes exposed outside
for more than four hours shall be returned to the oven.

Stress Relieving
All cold rolled plates, with thickness higher than 35 mm and/or one percent of the rolling diameter, to be
welded to each other shall be stress relieved after welding and before machining in order to eliminate the
internal stresses. In all the other cases, stress relieving shall be made when required by ASME Code for
Unfired Pressure Vessels. Stress relieving methods shall comply with ASME Standards.

Oil and Grease


All components in movement shall be duly and efficaciously lubricated. Greasing or lubricating points shall
be grouped for all equipment in easily accessible positions. Pressure gauges and level indicators shall be
installed in a noticeable place to acknowledge a sudden drop in level or pressure and prevent any damage
that may occur.
Dipsticks, leakage drip plates, lubricant sight glasses shall be installed throughout the Plant. All the
lubrication equipment shall be tested, before placing into service, at a pressure of 1.5 times the maximum
operating one. The Contractor shall entrust a lubrication schedule for the Equipment, showing the
recommended frequency of application and types and grades of required lubricants. The
recommended lubricants shall be approved by MoE before requiring their supply.
Type of oil and grease shall be reduced to a minimum so as to facilitate maintenance, and shall be available
in the local market. After MoE approval, the Contractor shall supply all first filling oil and grease. With the
first filling it is intended the 125% of the quantity necessary for the operation of the equipment.

Shop Preassembly
The Contractor shall preassemble, in its shop, unless otherwise specified, those assemblies, subassemblies
and pieces of equipment which require precise fit-up for field erection. Shop assembly shall be done after all
shop welding and machining has been completed. The Contractor shall make all assemblies available for
checking by MoE's representative. All interferences, errors in dimensions and inaccuracies in workmanship,
discovered during the shop assembly, shall be corrected.
Before disassembling, each item to be shipped separately shall be match-marked and identified in conformity
with the erection drawings. Marking shall be done in such a manner as to retain its legibility until field
erection is completed.

Inspection and Testing


All materials and components shall be subject to tests and inspection while in process of and upon
completion of manufacture, as prescribed in Conditions of Contract. Inspection and tests shall consist of:
a. tests and inspections specified in the following chapters of these Specifications;
b. tests and inspection required by applicable standards;

Page 27 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
c. additional tests and inspection as may be necessary in the opinion of MoE to
demonstrate compliance with the Specifications.
All deficiencies revealed by testing and inspection shall be rectified by the Contractor at its own expense.
Rectified components shall be subject to retesting and re-inspection of MoEs Representative.
Test reports shall be complete with all pertinent data, descriptions of apparatus and photographs to present
clear, concise and factual evidence of the tests.
No parts of the plant shall be shipped until all required inspections and tests have been completed and
approved by MoEs Representative.
Acceptance of test results or waiving of tests by MoE shall not relieve the Contractor of its obligations under
the Contract.

Nameplates
A stainless steel nameplate, showing the following information, shall be mounted on each major piece of
equipment:
Equipment designation;
Manufacturer's name and address;
Serial number;
Part number;
Date of Manufacture;
Main ratings.
Unless otherwise specified, indicating plates to be applied on panel and board fronts shall be of transparent
plastic material, white painted and black engraved. Text of name plates and indicating plates shall be in
English, in metric units and shall be submitted to MoE for approval.

Miscellaneous Metalwork and Handling Facilities

The Contractor shall provide and install, in respect of the plant to be supplied, the following miscellaneous
metalwork:

soleplates, bedplates, foundation bolts and anchor bolts;

floorplates and curbing, including covers for pipe and cable trenches, required for completing the
floors around and over the plant;
platforms, ladders, guards and handrails necessary for easy and safe access to the plant;
safety guards at each point where normal access would permit personnel to come within reach of any
moving item of plant;
lifting lugs, eyebolts or other lifting attachment points on each item weighing more than 250 N; in
case the pieces are of such a shape as to make the above devices uneven or anesthetic, handling belts
and brackets shall be supplied.
Particular care shall be paid in making handling and lifting of equipment as easy as possible, which requires
routing maintenance at Site. To this end wall hooks and manual removable winches shall be supplied for any
equipment out of crane range.

Packing and Identification


The Contractor shall be responsible, at its costs, for loading, transporting, shipping and unloading of the
equipment to be supplied under the Subcontract from the point of manufacture to the Site. The Contractor
shall furnish to MoE a complete program of delivery for the equipment, and shall provide revisions to this
program when necessary. The Contractor shall provide such packing of the equipment as is required to
prevent its damage or deterioration during transit to its final destination. Packing case size and weights shall
take into consideration, where appropriate, size and dimensions possible limitations at the location of the
equipment's final destination and the capacity of existing handling facilities.
All equipment and material required for the Subcontract which is being shipped shall be effectively protected
against corrosion, loss and damage and shall be adequately packaged for ease of handling and for shipment
Page 28 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
in cold climate, to avoid damage during train and road transport, and for outdoor storage at the Site during
extended period of extreme cold. Shipment of equipment by container system will be acceptable, but all
incidental expenses shall be borne by the Contractor. The cost of all damage to the equipment due to
improper packaging shall be at Contractor's expense. Machined surfaces shall be specially protected against
corrosion and shall be positively prevented from coming into contact with timber packing or supports,
paying due regard to movements which may occur during transport.
Flange faces and openings shall be covered by metal blanks and gaskets. Rubber parts shall be protected
against light and air. Moisture absorbent crystals shall be provided when items are enclosed in plastic or
other impervious material. Relays, instruments and the like shall be removed from panels and separately
packed. Each package shall be clearly marked with the Contract Number, package identification number,
gross weight, net weight, package dimensions, any special lifting instructions and with a brand to be
nominated by MoE. Each package or crate shall contain a copy of the packing list in a waterproof envelope.
All boxes, crates, cases, bundles, loose pieces, etc., shall be consecutively numbered from No. 1 upward
without repeating the same number throughout all shipments under this Contract. The Contractor shall
arrange for protection of the packages in outdoor storage at the Site. All packages shall be placed on packing
to raise them above ground level. If any item is unsuitable for outdoor storage, the Contractor shall agree
with the Employer a proper place indoor. All packing materials, except that required for storage of spare part
shall remain the property of the Contractor and shall be removed from the Site when appropriate.

Protection against Atmospheric Agents

General
All materials and equipment supplied under these Specifications shall be suitable for being delivered, stored
and operated under continental conditions with extreme changes in the temperature between winter and
summer and between day and night. Process for protection against atmospheric agents shall be in accordance
with the best commercial and industrial practices.

Metals
Iron and steel shall generally be painted or galvanized or metal-sprayed as appropriate. Indoor parts may
alternatively have chromium or copper-nickel plating, or other suitable protective finish. When it is
necessary to use dissimilar metals in contacts, these shall so selected that the potential difference between
them in the electrochemical series is not such as to cause galvanic corrosion. If this is not possible, the
contact surface of one or both of the metals shall be electro-plated or otherwise finished in such a manner
that the potential difference is reduced within the required limits or, alternatively, the two metals shall be
insulated from each other by a suitable insulating material or a coating of varnish compound.

Bolts, Screws, Nuts, Washers

Steel bolts, screws, nuts and washers shall be zinc, cadmium or chromium plated or, where plating is not
possible due to tolerance limitations, of corrosion-resisting steel. All wood screws shall be dull nickel-plated
brass or of other suitable finish. Corrosion-resisting steel, copper-nickel alloy or bronze, shall also be used
for bolts and nuts when either or both are subject to frequent adjustment or removal, or are in contact with
water and for bolts projecting from concrete with nuts to removal or vice versa. All Type 1 high strength
bolts (ASTM A 325) and associated nuts and washers shall be hot dip galvanized.

Fabrics, Cork, Paper, etc.

Fabrics, cork, paper and similar materials, which are not subsequently protected by impregnation, shall be
adequately treated with suitable fungicide. Sleeving and fabrics treated with linseed oil varnishes shall not be
used.

Adhesives

Adhesives shall be especially selected to ensure the use of types which are impervious to moisture, resistant
to mold growth and not subject to the ravages of insects. Synthetic resin cement only shall be used for
joining wood. Casein cement shall not be used.

Page 29 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Electrical Materials and Equipment
Materials and components which are inherently fungus resistant or are protected by hermetic sealing or oil
immersion need not be treated. Other elements shall be protected by additional varnish against humidity and
given an antifungus treatment.

Mechanical Details

General

All mechanisms will be made of first quality material, machined and mounted according to the most
advanced practice. The elements will be studied for perfectly resisting the stresses corresponding to
maximum torques. As a general rule, the use of cast iron is not admitted in the manufacture of elements that
are subject to bending or shocks and it will be tolerated only in the manufacture of supports, shoes, brake
sheaves. Each reduction gear shall be housed in a box fitted with a drain plug and with a device to check the
oil level. Bearings will be suitably sized and firmly fastened on sturdy trunnions. Covers of lubricating pipes
of bearings or shafts will be fitted with a small chain to prevent their fall. Any moving component shall be
encased in order to avoid accidents.

Drums
The pitch diameter of the drums shall not be less than 25 times the outside diameter of rope and/or 450 times
the diameter of the wire forming the rope. Drums shall be of first quality rolled steel. They shall be grooved
with a depth of at least 35% of the rope diameter. Two complete turns of rope shall stay wound on the drum
when the rope is unwound for the maximum depth of work. When the hook is in its highest position,
overlapping of the rope shall not be allowed. Each drum shall have right and left-hand grooves turned from
the solid, to receive the hoisting rope. The grooved length of the drums shall be sufficient to take the full run
of rope for the maximum lift plus two turns at each end. The rope connection to the drum shall be simple and
secure so that replacement of the rope shall easily be made. Drums shall be pressed and keyed to the drum
shaft. The drum gears shall be pressed and keyed to the drum body.

Sheaves
Sheaves shall be of solid rolled steel. The rope grooves shall be turned. Pitch diameter of rope grooves for all
moving sheaves shall not be less than 24 times the diameter of the rope, and for equalising sheaves not less
than 20 times the diameter of the rope. All sheaves shall be provided with roller bearings or bronze bushings.

Wire Ropes
The hoisting ropes shall be of the first quality and shall be made of steel wires resistant to corrosion, ultimate
tensile strength not less than 1 400 MPa. The safety factor referred to the ultimate tensile strength shall not
be lower than eight. The rope stresses shall be calculated according to the Standards.

Hooks and Blocks


The hooks shall be of forged steel, supported by thrust bearings mounted on a forged steel supporting beam.
The hooks shall rotate freely and the bearings shall be grease lubricated and totally enclosed to prevent dust
entry and grease leakage. The blocks shall be manufactured so as to protect the wire ropes and prevent them
from moving out from the sheave grooves during the slack rope operation. The protective guards shall be of
solid, welded construction, grease-proof type, mounted close to the sheave periphery. The rated lifting
capacity shall be marked with paint on the two sides of the block.

Shaft and Bearings


The shafts shall be made of high tensile rolled steel. Their diameter shall be calculated taking into account
key slots and any other resisting section reducing elements. The bottom of this slot shall be rounded off. In
any case the shafts shall be designed so as to limit the deflection to 1/3 000th of the distance between the
bearings. The bearings of the high-speed operating shafts shall be provided with ball rolling system; the
bearings of the low-speed operating shafts shall be provided with bushings or antifriction metal.

Page 30 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Gears
The tooth profile for all types of gears shall be carefully calculated and machined. All gears shall be made of
forged steel, exception made for the worm wheels that shall have replaceable outer crown made of highly
resisting bronze. The gears having revolving speed higher than 500 rpm shall have helical teeth and the
active contact areas shall be case hardened up to a depth of 2/10 to 3/10th of millimetre; identical case
hardening shall be foreseen for the worm screws. All the gears and reduction gears as well as the bearings
shall be oil-bath lubricated. According to their operating requirements, the bearings shall be made of bronze
or antifriction metal, or ball type, easy to replace. The reduction gears and the gears shall be totally enclosed
in sealed boxes made of cast steel or welded sheets, of very rugged construction, in order to ensure the
perfect alignment of axis and shafts and prevent their deformation during the transport and erection. The gear
boxes shall be provided with the accessories necessary for oil filling and emptying. These operations
shall not require the disassembling of any element of the box. It shall be possible to open the upper part of
the box, to allow inspection of the gears. As far as possible also lateral inspection panels shall be foreseen,
with hermetic seals. All gear safety factor shall not be less than five, referred to the ultimate tensile strength.

Wheels
All wheels shall be made of cast or forged steel. Wheel sizes shall be proportioned to the maximum wheel
loads and their diameter (in cm) shall not be less than L/120 W, where L is the wheel load in kg, W is the
effective width of the rail head in cm (excluding corner radii). Standard roller bearings, sealed type, or self-
lubricated bearings of well known manufacturers shall be adopted following the prescriptions of said
manufacturers.
Bearings with bronze bushing may also be accepted, subject to MoEs approval; these bearings shall be
grease lubricated and fitted with suitable grooves on the contact surface to ensure uniform lubrication. The
mean pressure on the bushings shall not exceed 10 MPa on the projected area of the bearing, under rated
operating conditions. The driving wheels shall be rigidly connected with a crown gear driven by a pinion.
The driving units shall mainly consist of a motor connected to the reduction gear by means of a transmission
shaft fitted with a cardan joint. The special jacks for disassembling the wheels shall be included in the
Supply.

Piping, Valves and Threaded Fasteners

General
All piping, valves and threaded fasteners shall be designed according to to ASME/ASTM Standards; the pipes
shall be in accordance with ASME B 31.1; all flanges shall be of Raised Face (RF), designed according to
ASME B 16.5. Screwed joints may be used for pipes up to 50 mm diameter, at working pressures not
exceeding 0.7 MPa. Pipes of 25 mm diameter and less, for working pressures exceeding 0.7 MPa, shall be
joined by unions of approved type. The working pressure of a system shall be taken as the maximum
pressure it can attain, including water hammer and/or relief valve blow-off pressure. The pipe diameters shall
be calculated considering the following maximum allowable speeds:
Air 15 m/s and 5 m/s in between compressors and receivers;
Oil and water at the suction side 1 m/s;
Oil and water at the pressure side 2.5 m/s.
The thicknesses of the pipes shall be calculated following the ASME requirements; at least 3 (three) mm for
corrosion shall be considered for the water and air piping and 1 (one) mm for the oil piping. All piping 100
mm nominal diameter and larger shall be completely prefabricated at Sub-Contractor's workshop with all
fittings in place, except that extra length for field cutting and welding shall be provided where required for
field assembly. Piping with flanged connections shall be furnished with gaskets, bolts, studs and nuts. All
pipes up to 50 mm nominal diameter shall be assembled by means of threaded or socket welded fittings.
Threaded and socket welded pipe will be Site fabricated, as erection proceeds. Piping systems shall be
complete with fittings, valves, supports and all necessary accessories. Piping arrangement shall be neat in
appearance and shall allow a convenient operation. Items requiring periodic attention shall be easily and
readily accessible from floors or platforms. Pipes shall neither obstruct passways nor interfere with access to
valves and equipment. The piping buried in the concrete shall be sloped for drainage and provided with 25
mm diameter drain valves at all low points in the system. The supports, hangers, anchors and clamps
necessary to support and restrain all pipes and valves shall be designed, selected and located in order to

Page 31 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
ensure uniform continuous slopes for draining and minimize stresses in the piping material, and to let the
piping system be safely supported, guided and anchored, especially for the pipes to be laid in the pier trench.
All items to be site welded to the piping shall be of the same material as that of the relevant piping.
As far as practicable, the supports shall be grouped and of consistent design throughout.
The Contractor shall submit for approval drawings showing:
1 the piping flow diagram;
2 the piping P. and I. diagram;
3 the piping layouts.
The Contractor's calculations of the piping diameters and thicknesses shall be available for approval at MoE
request. Axonometric sketches shall be supplied for site erection.

Pipes
Unless dictated by design conditions or OEM and vendor recommendations, Pipes shall be in accordance
with the ASTM A 53 Grade B standard specification or approved equivalent for welded and seamless steel
pipe. Type S, seamless pipes will be preferred. Longitudinal welded pipes type E, electric resistance welded
pipes, is subject to approval. All pipes shall be shipped with the ends plugged by plastic covers. The beveled
ends to be welded at Site shall be protected by a special paint compatible with the welding. Piping between
the fuel gas coalescing filter/separator and the gas turbine fuel gas connection shall be 316 SST. All
instrument air piping shall be 304L SST.
Elbows having radius at least 1.5 nominal diameter shall be used for changes in the direction of piping
having 75 mm nominal diameter and over. For piping having 50 mm nominal diameter and below
commercial fittings shall be used. Bends having radius not less than 5 nominal diameter instead of ells may
be used. Minimum wall thickness at any point of the elbows, bends and ells shall not be less than the
minimum wall thickness allowed for pipes. Shop prefabricated pieces may be employed for tee reducers,
drain and other special pieces. Materials and thickness shall be the same as for the straight pipe. Branch
connections shall be reinforced where necessary in accordance with the requirements of ANSI B 31.1 Code
for Pressure Piping. For piping having 50 mm nominal diameter and over, seamless type fittings such as tee,
reducers and cap shall be used for intersection of piping, piping branches, changes in size and end closure.
Metered fittings and metered bends will not be accepted. All ends of 250 mm nominal diameter and over
shall be internally calibrated for simplifying the welding at site. The misalignment between the internal
surfaces to two ends having the same diameter and wall thickness shall not be greater than 1.6 mm. Ends of
pipes of 65 mm nominal diameter and over shall be plain ends beveled in accordance with butt-welding and
preparation dimensions contained in ANSI Standards B 16.25. Ends of pipes of 50 mm nominal diameter and
below shall be plain end cut square. Open ends of pipe shall be plugged or otherwise suitably closed when
the work is suspended.

Valves
Unless dictated by design conditions or OEM and vendor recommendations All the valves except for
instrument air valves, dematerialized water system valves and those in SST fuel gas piping shall be of the
flanged type, made of carbon steel, with stem and sealing rings of stainless steel; all valves shall be provided
with back seated stems. Valve nominal diameter shall always be equal to the relevant pipe diameter. Seals
and seats shall be positively fixed so that they cannot become loose in service. The fixing of seals and seats
by an interference fit only is not acceptable. The operating mechanism shall have means of lubrication and
position indicators and, in the case of isolating valves, the means of padlocking in the open and closed
positions together with approved padlocks and keys. All hand-operated valves shall close by clockwise
rotation of the handwheels, which shall be marked to show the direction of closing. Valve handwheels shall
be located for safe and convenient operation with extended spindles where necessary to achieve this. All
hand-operated valves shall be capable of being opened and closed against their maximum working pressure
fully unbalanced with a force at the handwheel not exceeding 100 N. If necessary to achieve this, reduction
gearing, ball or roller bearings shall be provided. The valves noted above as not being made of carbon steel
shall be made of stainless steel that is compatible with their mating piping material.
As far as practicable, all valves for similar service shall be of the same make and type and be
interchangeable. All gate valves for water and air service shall be of a type in which the operating
mechanism is not subject to the working fluid. Valves other than needle type shall not be used permanently if

Page 32 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
the need for throttling is foreseen, such as to adjust flow subdivision in a system; orifice plates or needle
valves with fixed stops shall be provided.
Valves for water and oil service may be gate, butterfly, ball, plug or needle type, whichever is most suited to
the particular service and operating pressure. Valves for air service may be ball, plug or needle type
whichever is most suited to the particular service. Non-return valves shall be of a type specifically designed
to avoid impact and water-hammer on closure. The closing member shall be pivoted from the valve body, not
from a lid cover. Relief valves for pumps shall be of direct spring loaded, angle body type. For identification,
each valve of 150 mm ND and over shall be provided with stainless steel identification disc on the
handwheel.
On this disc the following shall be etched:
1 manufacturer;
2 catalogue number;
3 size;
4 rating and fluid;
5 trim material;
6 body and bonnet material.

Valves below 150 mm ND shall be identified with size and ASME Class.
The disc shall be written in English.

Threaded Fasteners
The threaded fasteners shall comply with ASME/ASTM standard system and with the following requirements:
1 steel bolts shall be forged, unless otherwise approved;
2 mild steel fasteners shall be zinc or cadmium plated;
3 all parts shall be spot-faced or machined for nuts or bolts, except in the case of clearance bolts in
structural steelwork;
4 tapped holes shall not be used in sheet metal less than 6 mm thick;
5 fasteners of less than 6 mm diameter shall not be used, except in instruments and relays;
6 threaded fasteners of more than 8 mm diameter shall have hexagon or socket hexagon heads;
7 all threaded fasteners subject to vibrations and/or installed in a position which is not inspectionable
during operation shall be locked in an approved manner.

Page 33 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Pumps
General requirements

All pumps supplied within the Contract shall be designed, manufactured and tested in accordance with
the requirements of the relevant Standards and Codes. Unless specified otherwise, centrifugal pumps
shall be designed, manufactured and tested in accordance with the relevant BS/ISO (ISO 5199, 9905 or
9908 as applicable) or equivalent internationally recognized standards.

The pumps shall operate satisfactorily when delivering varying quantities from minimum up to the
design maximum flow and shall be constructed to ensure continuity of service, ease of inspection,
cleaning and repairs, together with satisfactory operation under all climatic conditions prevailing at
site.

Where duplicate pumps for the same service are provided they shall operate satisfactorily in parallel
with each other.

All pumps shall be designed far maximum continuous operation conditions even at system frequencies
between +4 per cent of rated frequency. All pumps shall have a design margin of 10 per cent on flow
and 20 per cent on head.

The characteristic curve of a centrifugal pump shall be stable under all conditions, ie the head shall
increase with decrease in delivery until maximum head is reached at zero flow. Details of head and
flow/performance characteristic curves shall be submitted for design review. The Net Positive Suction

Head (NPSH) required at any capacity up to and including runout shall be at least 20 per cent or 1 m
less than the available NPSH, whichever creates the greater margin.

The pumps shall be free from vibration at all load conditions and shall be designed to allow
satisfactory and safe operation during all possible operating conditions, including cold and warm
startup and run out flow.

The pumps shall be designed in such a way that no leakage shall result from a change in fluid
temperature. In general mechanical sealing systems shall be used throughout.

Material shall be specifically chosen to resist cavitations, erosion and corrosion, seizure or other
destructive influences to which a pump may be subjected in service. If the pump impellers and the
impeller shaft are of different material, any portion of the impeller shaft which could be in contact with
the fluid must be covered by a sleeve of the same material as used in the impeller construction.

The general arrangements of the pumps, motors, supports, piping etc shall allow handling for
maintenance with the least possible dismantling and joint breaking. All structures and foundations etc
shall be designed, supplied, installed and tested under this Contract. This shall include steel wedges,
leveling screws, support plates, foundation plates and anchor bolts, etc.

All leakages shall be collected and directed to suitable drain connections and discharge system.

Flexible coupling with guards shall withstand all service conditions and shall be arranged for easy
disconnection and reassembly. Suitable connections for instruments drain and vents shall be provided.

Page 34 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

Types of pumps

Horizontal spindle pumps shall be of the centrifugal type with fully balanced impellers and at least two
bearings. The driving motors shall be mounted on an extension of the pump base plates. Baseplates
shall be provided with drip tray facilities and provision shall be made for drainage.

All pumps shall be capable of reverse rotation up to 125 per cent of rated speed due to back flow of
fluid without causing damage to the pump, alternatively a reliable method of preventing reverse
rotation shall be provided.

For certain services, the pump may be installed in a tank of suitable material which forms a well from
which the pumps takes its suction. Such tanks will normally be cast in concrete, with the discharge
flange above the floor level. Only the mounting and discharge flange bolts will require removal to pull
the pump.

Portable sump pumps shall be of the heavy duty submersible self priming type, each complete with 10
meters of flexible hose, sealed-off electric motor and flexible power cable 20 meters long. The power
cable/pump motor connection shall be completely waterproof when connected. All portable sump
pumps shall be suitable for pumping dirty water which may be contaminated with fuel oil.

All positive displacement pumps shall be of the horizontal screw or gear type.

All positive displacement pumps shall be complete with electric motor driver, common base plate, gear
type flexible coupling and base mounted coupling guard, arranged for easy disconnection and
reassembly and designed to withstand all service conditions. The pump/motor combination shall be
non-overloading at 125 per cent of the normal system operating pressure at the maximum pumping
viscosity value. Spacer type couplings shall be used if required to allow pump disassembly without
moving the motor. All pumps shall be direct drive.

Pumps of the rotary screw type shall have two (2) or three (3) rotors in accordance with
manufacturer's standard. Externally lubricated indexing gears and bearings shall be provided

Electrical Equipment

General

The following paragraphs cover the general requirements for electrical equipment, such as panels, boards,
distribution boards, auxiliary devices, motors, relays, indicating instruments, cables, etc. to obtain a
satisfactory uniformity of the equipment. The Contractor shall deliver the equipment within its Limit of
Supply, complete in all respect with all components, fittings and accessories, for an efficient and trouble-free
operation as required by the Technical Specifications. The Contractor shall submit to the approval of MoE all
electric drawings such as design basis for each system, single and three line diagrams, schematic and logic

Page 35 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
diagrams, overall dimensions, manuals, calculation sheets, equipment detail data sheets, cable list, cable
interconnection drawing, cable route diagrams, catalogue/leaflet for different equipment or part, etc.; the
drawings shall give a complete description of the principle of operation and of the construction details of the
component supplied by the Contractor. The Contractor shall clearly indicate on the drawings the limits of its
Supply, according to the Technical Specifications and to the Contract Drawings.

All electrical equipment shall withstand, without any damage or permanent deformation, the stresses
produced by whatever overvoltage and the maximum electrodynamic stresses produced by the short circuit
currents in the worst possible operating conditions.

The system voltages presently used in the plants, are the following:

Power centers, Motor control centers and main loads 400 V AC 10%, three phase, 50 Hz
5%

Lighting system, space heaters, minor loads 230 V AC 10%, single phase, 50 Hz 5%

Control equipment, inverters, emergency motors 110 V DC 20%

Emergency lighting, overall monitoring system 110 V DC 20%

Unless otherwise stated in the Technical Specifications, the prescriptions of this chapter shall be strictly
followed.

Motor Control Centers, Distribution Boards, Panels, Boards, Cabinets and Local
Control Panels
General

The Contractor shall supply and install Motor Control Centers, Distribution Boards, Panels, Boards, Cabinets
and Local Control Station included in the Limit of Supply, as called for in the Technical Specifications.

Motor Control Centers, Distribution Boards, Panels, Boards and Cabinets

General

The enclosures for indoor installation of Motor Control Centers, Distribution Boards, Panels, Boards and
Cabinets shall be IP 42 protection class or higher, unless otherwise stated in the Technical Specifications.
The enclosures shall be made of steel sheets having a minimum thickness of 2 mm, shaped and reinforced to
form a rigid free-standing structure. Any individual cubicle, module or compartment of enclosures shall be
provided with a hinged door to allow full access to the inside mounted equipment. The doors shall be
suitably gasketed to make the compartments dust-tight. Provisions shall be taken to prevent the possibility of
accidental contact with live parts when opening the doors. Doors shall be provided with key locks. All inside
equipment and connections shall be operable and accessible from the front of the enclosures. Busbars for
power circuits, when provided, shall be of copper, liberally dimensioned for the specified current ratings,
both short-circuit and continuous current. All joints and connections of busbars shall be silver plated. The
phase arrangement shall be A, B, C, counting front to back, top to bottom, or left to right, as viewed from
the front of the enclosure. Each phase shall be suitably identified by coloured marks to be defined by MoE;
in accordance with requirements of the Employer as far as identifications colours are concerned. Bus
supports shall be made of flame retardant material. Each enclosure shall be provided with a copper ground
bus having a minimum cross section of 200 mm and to which steel structure and all metallic parts of the
enclosure shall be connected. Grounding terminals and connectors shall also be provided at both ends of the
ground bus. Small sized panels, boards or cabinets can be provided, instead of the ground bus, with a
ground bolt. Motor Control Centers, Panels, Boards and Cabinets shall be designed considering the local
ambient conditions stated in these Specifications.

All enclosures shall be provided with thermostatically controlled space heaters, operated at 230 V, 50 Hz
from an external source. Heaters shall have individual automatic miniature circuit breakers. Each vertical

Page 36 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
section shall be provided with one space heater. The thermostat range shall be preferably 0-50C. Cable entry
shall be located at the bottom or at the top of the enclosures, according to layout requirements.

Enclosures shall be supplied complete with cable glands. Removable plates for fitting the cable glands shall
be provided preferably at both top and bottom of the enclosures. Suitable brackets to fasten the cables shall
also be provided. Motor control centers, floor mounted panels, boards and cabinets shall be supplied
complete with suitable base channel frames, anchor bolts and nuts. All cubicles, boards, panels etc., shall be
completely wired. External surfaces shall be painted in RAL 7030, while inside surfaces shall be treated with
anti-condensation paint.

Motor Control Centers

The Motor Control Centers will be used to supply the power and/or the control of 400 V AC motors up to
110 kW and as distribution boards to supply the power to loads fed at 400 V AC.

Unless otherwise stated in the Technical Specifications or shown in the Contract Drawings, the power circuit
of Motor Control Centers shall have the following main characteristics:

System three-phase, four wires, grounded neutral

Rated insulation voltage 660 V

Rated frequency 50 Hz

Rated short-time withstand current for 1 second 35 kA (rms symm.), or as required by


calculation, plug in contacts included

Motor Control Centers shall be intelligent, and made up of individual modules, arranged in vertical sections
with separations between each other. Each module shall have an independent MM300 Motor Management
Relay for connection to the plant control system. Non-motor loads shall have independent FM2 Feeder
Management Relays. The vertical sections shall be bolted together to form a rigid, free standing assembly of
uniform and neat appearance.

The module sizes shall be multiple of one basic unit to facilitate interchangeability. Modules of similar
function shall be interchangeable. The design of the Motor Control Centers shall permit their easy extension
on site at either end. The door of each individual module shall have a key lock and shall be so constructed
that it cannot be opened when the relevant main circuit breaker is in the ON position. Modules provided
for motor control (Combination Motor Control Units) or for non-motor loads (Feeder Tap Units) shall be of
the fully draw-out type, i.e. contacts for power terminals on both incoming and outgoing sides shall be draw-
out type.

Power and control terminals shall be installed close to each module and physically separated from each other.
Suitable interlocks shall be provided to prevent on-load withdrawal of draw-out type units. When the draw-
out units are taken out, suitable devices shall avoid accidental contacts with live parts. Automatically
operated shutters or similar devices will be accepted.

Motor Control Centers are typically composed by an incoming feeder, some feeder tap units and some
combination motor units, as required by the Technical Specifications and by the Contractor's load. Motor
Control Centers used as distribution boards are basically composed of an incoming feeder and of the required
number of feeder tap units. Incoming feeders shall have F650 protection & control relays. Unless otherwise
stated in the other sections of these Technical Specifications or shown in the Subcontract Drawings, the
Contractor shall follow the prescriptions given here below.

The incoming feeder cubicle shall be of fixed type, equipped as follows:

molded case circuit breaker with trip switching device, draw-out or plug-in type;

voltmeter, with scale 0-500 V;

Page 37 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
voltmeter switch, to read the three line-to-line voltages upstream of main circuit
breaker;

potential transformers 400/100 V (draw-out type);

auxiliary protective fuses;

F650 Feeder Management relay.

The feeder tap unit shall be draw-out type, equipped with molded case circuit breaker with built-in
thermomagnetic protective device and an FM2 Feeder Management relay for connection to the plant control
system.

Combination Motor Control Units shall be of fully draw-out type. They shall consist of:

molded case circuit breaker, with built-in magnetic protective device;

magnetic contactor (in the starters for reversing motors, two contactors mechanically
and electrically interlocked shall be provided);

Management relay; for overload protection and connection to the plant control system;

indicating lamps;

auxiliary protective fuses

The circuit of every Combination Motor Control Units shall include necessary devices, contacts, and relays
for the remote signaling of draw-out unit not available due to operation of thermal and magnetic protective
devices, test and draw-out position of the unit, control voltage loss, etc. A local indication shall also be
provided by means of an indicating light with amber cap. As a general rule, the Motor Control Centers shall
have only provisions for signaling motor operations. Should the other Sections of the Technical
Specifications or the approved schematic diagrams call for the control of the motors from the MCCs, then
the necessary push buttons, selector switches and/or any other necessary devices shall be supplied by the
Contractor. Control units for motors requested to re-start after a brief interruption of voltage supply shall be
equipped with the necessary relays and/or devices. or use the in-built feature of the MM300 to achieve the
desired re-start.

It shall be possible to reset thermal overload relays from the outside of Motor Control Centers, without the
necessity of opening the door. The Contractor shall be fully responsible for the good co-ordination of
equipment supplied under its scope of work. Particular care shall be applied in co-ordinating the equipment
for Combination Motor Control Units in order to protect the contactors and thermal overload relays in case
of short circuit faults. To provide facility for inclusion of interlocks, the motor control circuits shall be
developed with suitably located breaks provided on the terminal block and bridged up with jumpers. The
Contractor shall supply the auxiliary relays required to multiply the auxiliary contacts of the main
equipment, as shown in the approved schematic diagrams.

Boards, Panels and Cabinets

Boards, Panels and Cabinets shall be provided either for control or power supply or for the combination of
power and control circuits. Boards, Panels and Cabinets shall be designed for floor or wall mounting. The
Contractor shall include in its Supply all necessary fittings for the installation of wall mounted type
enclosures. Where applicable, suitable interlocks shall be provided to prevent door opening with the main
disconnecting device in the ON position. Boards, Panels and Cabinets which include power circuit shall be
provided with an incoming trip-free circuit breaker. A voltmeter with a selector switch and potential
transformers shall also be supplied. Loss-of-potential relays or other relays shall be supplied as shown in the
Subcontract Drawings. When Combination Motor Control Units shall be supplied, the units shall be as
described for Motor Control Centers in the point 4.10.2 above. They shall be equipped with indicating lamps

Page 38 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
and with START and STOP push buttons. STOP push button shall be fitted with lock and key, to avoid the
possibility to start the motor when the key is removed.

Suitable LOCAL-REMOTE selector switch, with removable key, shall also be provided when remote control
is called for by Technical Specifications or by approved schematic diagrams. It will be possible to remove
the key only when the selector is in the REMOTE position.

With the selector switch turned on the REMOTE position, only remote starting of the motor shall be
possible, and conversely with the selector switch in the LOCAL position, starting the motor shall be
possible only from Board, Panel or Cabinet without any control from other sources. It shall always be
possible to stop the motor either locally or remotely, regardless of the position of the selector switch. The
change of position of the selector switch from LOCAL to REMOTE or vice versa shall not influence the
status of the motor. The Boards, Panels and Cabinets shall also be provided with AUTO-MANUAL selector
switch, should motors be requested for automatic operations.

Construction Features of Local Control Panels

A Local Control Station shall be provided for each motor, wherever required. Local Control Stations shall be
located in the proximity of the controlled motors and shall be equipped with indicating lamps, push buttons,
LOCAL-REMOTE and AUTO-MANUAL selector switches, as described above. All Local Control Stations
shall consist of sheet metal enclosures, complete with terminals and those intended for outdoor installation
shall have weather-proof enclosure. Suitable stands shall be supplied to support the Local Control Stations.

Molded Case Circuit Breakers

Molded Case Circuit Breakers (MCCB) shall be either three-pole or four pole for three-phase circuits, and
two-pole for direct current and AC stabilised system circuits. They shall have built-in protective devices or
shall be trip-free or with trip switching device, as specified elsewhere. Each circuit breaker shall be
capable of interrupting the rated short time current (rms, symmetrical value) required for the enclosure on
which it is installed. Fused circuit breakers shall not be accepted. If necessary, current limiting circuit
breakers shall be provided to obtain the requested interrupting capacity. The rated continuous current shall be
selected with a large safety margin, according to the load requirements. The contacts of circuit breakers shall
be silver plated. The handle of automatic MCCB, after the breaker has tripped due to a fault, shall occupy a
middle position. The incoming circuit breakers rating shall be selected considering all available modules
including feeders and spares. The protective device of the incoming circuit breaker, if provided, shall always
be co-ordinated with that of any downstream feeder circuit breaker. Circuit breakers shall be suitable to be
mounted inside steel cubicle

Magnetic Contactors

The magnetic contactors shall have three poles. The contactors shall be provided with a minimum of two
normally open and two normally closed auxiliary contacts, and both main and auxiliary contacts shall be
silver plated. Contactors shall be for indoor service, mounted within a steel cubicle. They shall be suitable
for full voltage starting of AC motors or miscellaneous loads, taking into account their installation
conditions. Rated continuous current of contactors shall be chosen to suit the rated current of motor or the
load to be fed. The selection shall take into account a large safety margin. The admissible short-time current
of contactors shall be co-ordinated with the protective device preceding it. Contactor coils shall be rated at
230 V, 50 Hz and must be able to operate without any trouble under a voltage supply within 110 and 80
percent of the rated value.

Thermal Overload Relays

Each Combination Motor Control Unit shall be provided with intelligent, microprocessor based MM300
Motor Management Relays. The relays shall be of a manually reset type. The Contractor shall be fully
responsible for the selection and co-ordination between breaker trip and overload relay setting, to provide
optimum protection and discrimination of the various circuits and equipment. The setting range of the relays
shall preferably be adjustable from 80% to 120% of the rated current. The Contractor shall co-ordinate the
overload relay and MCCB with the thermal overload characteristics of the motor, so that these protect
completely the motor. These protective devices should not operate during the starting phase of the motor. The
Page 39 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
admissible short time current of thermal relays shall be co-ordinated with the protective device preceding it.
The co-ordination of thermal relay, contactor and MCCB shall be in accordance with IEC Standard 947-4-1.

MV and LV Indoor Current and Potential Transformers

Unless otherwise specified in the Subcontract Drawings, the Current Transformers (CTs) shall be mounted
on the stationary structure of the cubicle preferably in the cable termination chamber, or in the generator bus
duct, as the case can be. Unless otherwise specified in the Technical Specifications. CTs mounted on
withdrawable chassis are not acceptable. The Current Transformers shall be installed in such a manner as to
allow an easy accessibility and replacement. The Current Transformers shall be single ratio, single or
multicore, epoxy impregnated bushing type. Secondary current rating of CTs shall be 5 A, while the other
technical characteristics (burden, accuracy class, etc.) shall meet the requirements of the relevant feeder or
those shown in the Contract Drawings. The compartment of potential transformers cubicles shall be fully
draw-out type. When the PTs are fully drawn-out, the primary terminals shall be automatically disconnected
and earthed. Automatic safety shutters shall be provided to cover up live terminals when PTs are drawn-out.
The PTs shall be cast epoxy resin insulated, with high dielectric strength and high partial discharge
inception voltage. When required they shall be of the antiferroresonance type; the resistor for quick damping
of ferroresonance oscillations shall be open-delta connected. The primary windings of PTs shall be protected
by medium voltage current limiting fuses, accessible only in drawn-out position. The secondary terminals of
individual PTs shall be protected by automatic miniature circuit breakers, with auxiliary contacts for remote
signaling of tripping, and wired up to the secondary terminal blocks, located in a suitable compartment of
one cubicle. Secondary voltage rating of PTs shall be 100/3 and 100/3 V, as the case requires, while the
other technical characteristics shall be in accordance with the prescriptions given in the Technical
Specifications.

CTs and PTs shall be designed and tested in accordance with IEC Standards.

Terminal Blocks

The terminal blocks shall be supplied installed on a DIN profile and suitably located to make easy cabling
installation and inspection. The terminal blocks shall be molded plastic, designed for ring-tongue crimp style
cable termination, unless otherwise specified. Screw type terminals, with screw directly impinging on
conductors, are not acceptable. Insulating barriers shall be provided between adjacent terminals. Terminal
blocks shall have separate terminals for incoming and outgoing wire and not more than three wires shall be
connected to inside terminals, and only one on the outer side. Terminal blocks shall be grouped according to
circuit functions.

Terminals shall be serially numbered according to the relevant wiring diagram. At least 25% spare terminals
shall be provided in each block. Control terminal blocks shall be suitable for connection of two 3.5 mm 2
stranded copper wires at each end. Terminal blocks for auxiliary supplies from external source shall be
suitable for minimum 10 mm2 copper wire. Minimum clearance of 200 mm shall be maintained between the
terminal block and the bottom or top plates to make easy the connection of outgoing cables. Terminals for
current transformer secondary circuits shall be shorting type, while those for potential transformer circuits
shall be sectionable type. Plugs for measuring instruments insertion shall also be provided. Terminals of the
sectionable type can be provided for circuits other than current transformer, subject to approval.

Auxiliary and Time Delay Relays


General

All auxiliary and time delay relays to be supplied and installed shall be vibration-proof and shock proof. All
relays shall be capable of operating continuously from 80% to 110% of the rated voltage of the circuit they
are connected to. The contacts of relays shall be single-pole, double-throw type. Both the moving and
stationary contacts shall be made of solid silver or special alloy.

Final Stage Relays

All relays pertaining to the final stage of each individual control system shall be heavy duty, of approved
type.
Page 40 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The minimum requirements of the final stage relays shall be as follows:

- Rated operational voltage 110 V DC

- Mechanical life (number of operations 10x106

- Insulation voltage 300 V

- Contacts:

quantity (convertible type) 4 NO + 4 NC

rated thermal current 10 A

breaking capacity at 110 V DC with DC inductive load L/R = 20 ms 2 A

The Contractor shall provide necessary auxiliary relays in case field indicating instrument and switches, such
as pressure switches, thermostats, etc., are requested to multiply their contacts for remote purpose. In this
case the relays shall comply with the prescriptions specified for the final stage relays.

Auxiliary Relays for General Use

Auxiliary relays to be provided for general use, such as contacts duplication for local signaling, interlocks,
etc., shall have the following minimum requirements:

- Rated operational voltage 110 DC

- Operating voltage range from 80 to 110 %

- Insulation voltage 300 V

- Rated thermal current 10 A

- Contacts:

quantity (change over type) 2 NO + 2 NC

breaking capacity at 110 V DC with DC inductive load L/R = 20 ms 1A

Time Delay Relays

The Contractor shall include in its scope of work all the time delay relays called for under Technical
Specifications or requested to reproduce the approved schematic diagrams. The time delay relays shall be
analogue or digital solid state type and shall have adjustable time delay. The operating coil shall be suitable
for continuous duty and shall have a voltage rating of 110 V DC. The operating voltage range shall be within
80% and 110%. The contacts shall be single pole, double-throw and shall have the minimum requirements
specified for the auxiliary relays in the previous point.

Fuses

All control and power fuses shall be cartridge type fuses. Plug fuses (screw-in-type) shall not be accepted.
The rated current of fuses shall be selected to suit the load and fault requirements. In the case control and
power fuses are used, auxiliary contacts shall be provided for fuse blown indication.

Indicating Lights

The indicating lights shall be provided wherever called for and mounted on the front door of enclosures for
electrical equipment. Indicating lamps and their holders are preferred with pin type. Lamps shall be
Page 41 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
filament type, with integrally mounted series safety resistor in DC circuits and with small transformer in AC
circuits. Caps shall be dust tight and shall have poly-carbonate or equivalent coloured lenses. Indicating
lights shall be so constructed that the lamp can be readily fitted and removed and the lens changed from the
front of the panel. When the local control board or cabinets are requiring signaling, these shall be grouped in
a suitable dust-proof, back-connected, flush-mounted box, with provision of 20% spare but not less than 5.
Two lamps, parallel connected, shall light individual windows separated from each other. Each window
cover shall be made of a white translucent material, with the name plate engraved with black letter. Test lamp
push-button shall be provided.

DC/DC Converter
Wherever DC/DC conversion must be used, two DC7dc converters in parallel through the coupling diodes,
one in standby to the other shall be provided.

Electrical Control Devices Manually Operated


a. General

The contacts in all electrical control devices shall be adequately rated for the service conditions.
Contacts shall be made of silver or special alloy and shall be double-break type. All control devices
shall be heavy duty, dust-tight type. Devices for outdoor installation shall be weatherproof type.
Where necessary, contacts shall be furnished for remote signaling interlocking etc.

b. Control Instruments and Selector Switches

Unless otherwise stated in the Technical Specifications, the control, instruments and selector switches
shall be of the multistage, rotary type, rated 300 V, 20 A continuous duty for both AC and DC service,
and shall be designed for switchboard mounting, with all contact mechanism behind the panels. Each
contact shall be of the renewable, self-cleaning and wipe-type. A square or rectangular front-of-panel
escutcheon plate shall be furnished and engraved to show the switch position.

i. Control Switches

Control switches shall be of the rotating and push type, spring return to neutral. Control switches for
Circuit Breaker and Disconnecting Switches shall be of four positions, READY TO CLOSE
READY TO OPEN with only the two outer positions CLOSE OPEN push type. The control
switches for Circuit Breakers and Disconnecting Switches shall be equipped with discrepancy light.

Control switches shall be arranged to turn as follows:

Clockwise: for RAISE, CLOSE (switches), START, ON and OPEN (valves)


position;

Anti-Clockwise: for LOWER, OPEN (switches), STOP, OFF and CLOSE (valves)
position.

ii. Instrument and Selector Switches

They shall be provided to select a particular mode of plant operation or different reading of
instruments. Instrument and selector switches shall have standard type handle and fixed operating
positions. Synchronising switches shall have standard type, removable handle in OFF position only
to insure that only one set of potentials can be applied to the synchronising equipment at one time.

iii. Pushbuttons

Pushbuttons shall be rated 300 V, 10 A, continuous duty for both AC and DC services.

Pushbuttons shall be shrouded type to prevent accidental operation. Where required, red and green
pushbuttons shall be provided for the following purposes:

Page 42 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Green pushbuttons: for RAISE, CLOSE (switch), START, ON and OPEN (valves) operations;

Red pushbuttons: for LOWER, OPEN (switches), STOP, OFF and CLOSE (valves) operations.

Green pushbuttons shall be mounted on the right hand side of the red ones, looking at the front of the
panel.

Pushbuttons on electronic equipment are excluded from the requirements of this subparagraph.

Electric Motors

The present paragraph covers the specifications for the electric motors to be supplied and installed indoors or
outdoors. All motors shall be of Totally Enclosed Fan Cooled type (TEFC), Class F insulation system, both
for outdoors and indoors service. All motors installed outdoor shall be designed considering also the
temperature increase due to sun radiation. All 3-phase high efficiency induction motors shall be of squirrel
cage rotors type and designed for full voltage starting. Voltage rating of motors shall be 400 V, 50 Hz. Motor
capacity shall be always not less than 120% of the maximum calculated required capacity. Motors shall be
capable of three consecutive starting when they are cold and two consecutive starting when they are at
normal operating temperature; the temperatures shall not exceed the limits stated in the IEC Standards for
Class B insulation system.

The starting current for 3-phase induction motors shall not exceed 10 times the rated current, when started
under normal conditions of supply voltage and frequency. The starting torque shall not be less than 100% of
rated load torque of the motor. The break down torque shall not be less than 200% of the rated load torque of
the motor. During the automatic change-over (1 to 2 s), the motors shall be capable of restarting or regaining
speed with a voltage 20% lower than normal voltage, without injurious heating.

The slip at rated output must not be more than 5% for motors up to 50 kW or 3% for motors above 50 kW.

The journal and thrust bearings of each motor shall be self-lubricated, with a self-contained cooling system,
and where necessary the bearings should be electrically isolated to prevent the passage of stray currents.
Whenever possible, the motor and driven auxiliary shall have a common baseplate. Every motor larger than
150 kW will be provided with at least 3 temperature detectors embedded in the stator windings and one
temperature detector in each of the motor bearings, wired up to the terminal box.

The motors shall be sized 120% of the expected load.

All motors shall be insulated in Class B, in accordance with IEC Standards unless otherwise specified.

The maximum operating temperature of the insulating materials shall not be higher, under any circumstance,
than the limits established in the Standards for the class of insulating materials. Noise level of electric
motors, either on-load or no-load, shall not exceed the overall pressure level of 85 dB (A), measured at a
distance of 1 m from the major surface of the machine.

All the motor terminal boxes shall be capable of rotating by 360 in steps of 90. All motors shall be
statically and dynamically balanced. Vibration amplitude shall be in compliance with the Standards.

The motors shall be able to operate for 2 min at a speed equal to 120% of the rated one.

All motors shall be complete with the following accessories:

terminal connection box;

space heaters and temperature detectors terminal boxes (if provided);

nameplate, according to Standards;

earth connections;

lifting eyebolts;
Page 43 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
baseplate and foundation bolts;

special tools for disassembly.

Boards and Panels Wiring

All wiring within the enclosures for electrical equipment shall comply with the requirements of this
paragraph. All electrical connections outside the enclosures for electrical equipment shall comply with the
cabling requirements of paragraph 4.9.14. Wiring shall be done with stranded copper conductor, flexible,
PVC insulated, switchboard wire. Conductors shall be of the fire retardant type, in compliance with the latest
edition of IEC publication 332, part 3. The rated voltage shall be 450/750 V. The PVC compound shall be
suitable for low temperature. Minimum cross-section shall be 1.5 mm 2 for control and auxiliary cables, solid
state circuits, 1.5 mm2 for other circuits rated 110 V, and 4 mm 2 for current and potential transformers. Each
wire shall be identified at both ends with wire designation, in accordance with the approved wiring schemes.
All wire terminations shall be made with compression, solderless type connectors and wires shall not be
spliced between terminal points. All series-connected switchgear devices shall be connected in the sequence
shown on the approved schematic diagrams. The wires shall be suitably grouped in bundles by means of
non-metallic wiring cleats or bands, with each bundle adequately supported along its run to prevent sagging
due to flexibility or vibrations. Where troughs will be used, they shall be non-metallic or grounded metallic
type, filled at not more than 60% of their cross-sectional area. All interpanels wiring, between different
modules of the same enclosure, shall be included in the Supply. The wiring shall be complete in all respects
to ensure the proper functioning of control, indication, protection, measurement and interlocking diagrams.

Low Voltage, Control Cables and Accessories

The Contractor shall supply and install low voltage power and control cables, cable trays, supports,
connection boxes, steel conduits, conduits coupling and threaded connectors, flexible conduits, clamps,
fixing bolts, cable joints and identification markings within its limits of supply.

Cabling Design

The Contractor shall prepare and submit for approval the termination diagrams and cable chart for all
electrical equipment and cables included in the Contract All cables shall be allocated a cable identification
number in accordance with the above cable schedules.

The cable schedules shall be of an approved format, showing for each cable:

cable identification number;

the termination points, identifying the location of the two cable ends in separate columns by
cubicle designation or device description with, where applicable, the device number as shown on
the circuit diagrams;

the details of cable (type and rated voltage, conductor size, number of cores);

the estimated route length, in metres.

The termination diagrams may be combined with equipment wiring diagrams. The termination diagrams
shall show the following details for each cubicle, cabinet, device or other equipment to which cabling is to be
connected:

cubicle designation;

all terminal strips or terminals in their correct relative location;

a wire number (or blank space in the case of a spare terminal) against each terminal;

for each cable, the cable identification number, the total number of cores and the number of spare
cores and the destination of the cable;

Page 44 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
the wire number of each core in each cable.

The termination diagrams shall make reference to the associated circuit diagram drawing numbers and
wiring diagram drawing numbers (if on separate drawings) including the latest revision number or letter. The
information may be presented in a schedule or tabular form (such as computer printout) provided that the
schedules are accompanied by drawings showing the terminals and the reference to the schedules to enable
easy cable, core and terminal identification. The Contractor may, subject to approval, employ for part of its
cabling system a standardized system of preformed cables, with plug and socket connections to facilitate
initial installation, operation and maintenance and later modification by the Employer. For such a system, an
alternative method of identification of connections may be employed in place of identification of circuit
wires, cables cores and terminals by wire numbers. The Contractor shall supply all components of the
preformed cabling system where this is employed.

Segregated cables shall be used for the following circuits categories:

DC controls and interlocks;

signaling and alarms circuits;

current transformer connections;

voltage transformer connections;

AC power circuits;

DC power circuits;

special measuring circuits (RTDs, TCs, etc.).

The Contractor shall allow for the following minimum number of spare cores in each
multicore control cable:

No. of cores in cable Min. No. of spare cores


2 nil
4 nil
5 1
7 2
12 2
19 2
24 3
27 4

Rated voltage of low voltage power cables shall be 0.6/1 kV. Cables shall have multi-core stranded copper
conductors, PVC insulation, wrapped with appropriate filler and core binder, galvanised steel wire or tape
armour and an overall PVC sheath.

PVC compound shall be suitable for low temperature. Single core power cables, if provided, shall be
armoured with non-magnetic metal tape.

The Contractor shall dimension the cables, taking into account the applicable Standards and the following:

Load ratings;

Short-time current, both in amplitude and duration;

Voltage drop.
Page 45 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Dimensioning methods and calculation sheets shall be submitted for MoEs approval. The short-time current
value to be introduced in the calculation of power cables shall be the maximum that can be expected at the
load terminals for a bolted short circuit fault, whether phase to phase or phase to ground. For all the power
cables of the 400 V AC Power Centers, the duration of short time current to be introduced in the calculations
shall be one (1) second. For all the power cables of the Motor Control Centers, the duration of short time
current to be introduced in the calculations shall be the break time of relevant circuit breaker installed on the
cable. The maximum admissible temperature after a short circuit fault shall be the one specified by IEC
Standards for the type of insulation adopted, assuming that the cable is at rated temperature of 100% before
the fault occurrence. The maximum total voltage drop on both feeders and branch circuit to the farthest
outlet, i.e. between the service entrance equipment and the connected load, shall not exceed five percent
(5%) in steady state operation. During motor starting the allowable voltage drop is ten percent (10%). In any
case the minimum cross-section of power cable cores shall be 6 mm.

Single core power cables shall be installed in trefoil touching formation. The requirements for multicore
control cables shall apply to all cables for the control, protection, indication, instrumentation and alarm
circuits, including cables from the DC and essential AC distribution boards, where such circuits are loaded to
less than 35% of the rated capacity of the cable. (For continuous loading over 35%, those cables shall be
regarded as auxiliary power cables).

Except for low signal, alarm and solid-state circuits, multi-core control cables will be circular copper
conductor, PVC insulated, wrapped with appropriate filler and core binder, non-magnetic metal screened of
max. resistance 50 /km at 20C and minimum thickness 0.1 mm, and overall sheathed with PVC, 0.6/1 kV
rating voltage, to the requirements of IEC Standard.

Multicore control cables for low signal, alarm and solid-state circuits shall be copper twisted pair, PVC
insulated, PVC sheathed and screened telephone type cables. PVC shall be of fire-retardant type, with
reduced flame-spread properties and reduced emission of smoke, corrosive and toxic fumes, in compliance
with IEC 332, Part 3, and suitable for low temperature. The minimum cross-sectional area for low signal and
solid-state circuit cables will be 1.5 mm2.

The minimum cross-sectional area for multicore control cables shall be at least 2.5 mm 2, unless otherwise
specified. Conductors for current transformer secondary circuits shall be designed with a cross-sectional area
of not less than 6 mm. Where the burden of the leads associated with the current transformers requires to be
further reduced to ensure correct operation of the equipment under all conditions, a larger cross-section shall
be used. In these cases the required cross-sectional area of the conductors shall be shown on the circuit
diagram. Conductors for voltage transformer secondary circuits shall not be less than 2.5 mm in cross-
sectional area.

Mineral-Insulated Metal-Sheathed (MIMS) cable shall not be used unless specifically otherwise stated in
these Specifications. The cores of power supply cables shall be colour-coded as set down here below.

AC (three-phase) supply cable - Phase R Red

- Phase S Yellow

- Phase T Blue

- Neutral Black

- Ground Green / yellow

DC supply cables - Positive leads Black

- Negative leads White

The cores of multicore cables may be colour-coded or numbered.

Cables Connection

General

Page 46 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Contractor shall connect the cable cores of each cable which terminates on all equipment supplied under
the Contract

The connections, using materials provided by the Contractor, shall include the following:

fitting an approved lug to each core (except spare cores);

fitting an approved phase or polarity identification to each power cable core and
identification ferrule to each control and alarm cable core;

where a wire number changes, all cores and wires on a terminal block shall be
double ferruled to show both wire numbers;

connections to equipment terminals (except spare cores).

Termination of Power Cables

For power cables, all cable cores shall be terminated. The Contractor shall ensure that AC cables are phased
and that the polarity of DC cables is correct.

Termination of Multicore Control Cables

For control cables, all cable cores except spare cores shall be terminated. Allowance shall be made by the
Contractor for each core to be sufficiently long and neatly looped to allow a fresh termination to be made,
should the original termination device break off. Where not enclosed in ducting, the unsheathed portion of
the cable shall be laced neatly with an approved non-flammable cable strapping. Spare cable cores will not
be terminated but should be sufficiently long to reach the most remote terminal strip in the enclosure. Spare
cores will be looped together and left in cable ducting inside the enclosure.

The Contractor shall provide approved non-flammable wire-marking ferrules on each core of all control
cables. Spare cores shall be identified with the letter S followed by the cable number. Cable cores in
control cables shall be terminated using ring tongue crimp style termination, unless otherwise specified.

Termination of Cable Screens

Unless otherwise specified, the screens of screened cable shall be earthed at one end only. This shall
generally be the end closest to the source of supply. Earthing of copper screens shall be by means of
wrapping three or more turns of 1 mm2 stranded copper earthing conductor over the exposed screen and
making an effective soldered joint with the screen. The earth conductor shall be terminated to the ground bar
of the equipment by means of crimp-on terminal lugs. All earthing conductors shall be insulated.

Cables Installation

Power and control cables shall be installed either on cable trays or inside concrete cable trenches or in
conduits. Cables shall be positioned so that they can be easily inspected and, if necessary, replaced. Both for
indoor and outdoor installations, the cable arrangements shall be so designed as to separate power cables
from control cables.
Good engineering practice is to be followed for tray loading with cables, conduit fill with cables, tier
separation and spacing.

The cables shall be laid in an orderly and neat manner; they shall be fixed at proper points by means of
clamps. For every type of installation, the laying of a new cable, in the case of breakdown of the old cable,
should be as rapid and straightforward as possible; in particular, all cables installed in conduits should be
easy to withdraw. The cables shall be installed in order to permit sufficient air circulation. Cables laid on
cable trays or cable racks shall be supported in such a way as to avoid damage to the insulation. Greasy or
oily substances shall not be used to facilitate the passage of the cable in conduits; only dry powdered
soapstone shall be permitted. The pull shall be applied to cables only by means of approved grips and the end
portion of the cable which has been marked or deformed by the grip shall be cut off. All the lengths of cable
running along a structure, pole or any other power plant or substation component shall be protected by a rigid

Page 47 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
galvanised steel tube or PVC conduit, as approved by the Main Contractors Representative. All types of
cables shall be placed according to the following prescriptions, provided the requirements for cable
installation according to Standards are strictly followed in addition to the prescriptions.

Outdoor Areas

In covered trenches or galleries: laid on cable trays;

In tubes or conduits: laid in concrete tubes or galvanised conduits; these


tubes or conduits shall be fitted with adequate junctions
and connection boxes, the whole installation being
waterproof and sealed;

Indoor Areas

At sight: laid as cable cluster in cable racks or cable trays, hung


from the ceiling; connections from the cable racks or
trays to the equipment shall be carried out in
steel conduits;

In covered trenches: laid on cable trays;

Embedded: pulled into galvanised steel conduits.

Cable Trays

The Contractor shall supply all cable trays necessary to support the cables connecting different parts of the
Supply. All trays shall be aluminum or galvanised steel, suitable for installation of insulated cables. The
hanger clamps, fastening hardware and pins shall be of highly corrosion resistant metals. Steel accessories
shall be galvanised. The trays shall have bottom slots not in excess of 50 mm in width. The quantity of
hanger clamps, fastening hardware and pins shall be as required to support all trays every 1.5 m. Cable trays
shall be of modular type. Connection to walls and to ceiling shall be carried out by interposing steel beams to
allow reasonable adjustment during the erection. The Contractor shall perform all the works for fixing the
cable trays to the trenches and for passage of cables through the walls. Cable trays shall be connected to the
grounding system by means of a ground wire or ground bar. Steel cable trays and accessories shall be hot-dip
galvanised. Supports shall be pre-assembled type and hot-dip galvanised. Separation between different class
of cables can be obtained through galvanised steel plate separators.

In order to protect cables, where cable trays are exposed to dust or light materials fallout, the same shall be
protected by suitable covers. In vertical sections, covers shall be installed for 2.5 m from the walkable floor.
Covers shall be in steel plate and dimensioned to withstand a load of 70 kg for every 4.0 m of length. Covers
and relevant accessories shall be hot-dip galvanised. Bolts and nuts shall be in stainless steel.

Conduits

The Contractor shall supply and install the conduits and the associated materials, such as conduit couplings
and thread protectors, flexible conduits, bushings, locknuts, unions, watertight conduit hubs, flexible conduit
fittings, cabinets, boxes and supports. The required quantities of the various items of conduits and associated
materials shall be furnished in accordance with the installation requirements. All complete piping shall have
a protection degree not less than IP54. All rigid steel conduits, couplings and elbows shall be hot-dip
galvanised rigid mild steel, in accordance with the latest revision of IEC and ISO Standard. The conduit
interior and exterior surfaces shall have a continuous zinc overcoating of transparent enamel, transparent
lacquer or zinc chromate. All conduits shall be furnished in 3 m lengths. Each 3 m length of steel conduit
shall be threaded at both ends and shall be supplied complete with a coupling on one end and a thread
protector on the other. The thread protector shall have sufficient mechanical strength to protect the threads
during normal handling and storage. All bends in the conduit shall be made cold and the radius of bends shall
not be less than nine times the conduit diameter; conduits flattened during bending shall be rejected. All
flexible conduits shall be plastic jacketed, liquid tight, galvanised steel.

Page 48 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Grounding Connections
The Contractor shall provide the necessary facilities to permit the easy connection of the equipment supplied
by him to the grounding system.

Control, Protection, Signaling and Metering Equipment

General

The main machinery supplied under these Technical Specifications will be provided with protection and
signaling devices. Primary signals and tripping signals shall be transmitted by direct current by means of an
energising voltage impulse. Should the Contractor wish to adopt a de-energizing circuit, the proposal shall be
submitted to MoE's approval. The control and protection contacts and circuits shall be completely separated
from the signaling and metering ones. Tripping contacts shall operate directly on the final stage relay without
interference with other circuits. The control circuits shall be protected with miniature automatic circuit
breakers, in order to exclude a part without affecting the general operation. The miniature automatic circuit
breakers shall be provided with at least 1 NO/NC auxiliary contact, wired to terminals for remote indication.

Instruments
General

The instruments shall be long scale (at least 210 degrees) antiparallax type, with white dials, black marking
and black pointers. The maximum scale value shall be at least 20% higher than the rated value. They shall be
vibration proof. Rated value or operating range shall be marked in red on the instruments. Field instruments
shall be grouped in panels where possible. Instruments to be installed on the same panel shall be similar in
shape, colour and dimensions. Instrument accuracy, dials and ranges shall be in accordance with the
applicable IEC Standards. All field instruments shall have weatherproof case. Instruments and switches
provided with contacts shall have electrically separated contacts for alarm and trip.

Contacts rating shall have continuous current carrying of 10 A and 1 A breaking capacity at 110 V DC,
inductive load L/R = 20 ms. In all cases, the ratings of contacts shall match with the requirements of
controlled loads, such as final stage relays.

Electrical Indicating Instruments

Unless otherwise stated in the Technical Specifications, all electrical indicating instruments to be mounted on
enclosures for electrical equipment, such as switchboards, MCCs, panels, etc. shall follow the prescriptions
given in this paragraph. These instruments shall receive an electric input signal from metering devices. The
instruments shall be moving coil, flush-mounting, dust-tight type, with 1.5% accuracy, within a temperature
range from 15 to 80C, a voltage range of 10% and a frequency range (where applicable) of 1% of the
rated values. The scale of ammeters in motor circuits shall be compressed type. The instrument case shall be
adequately grounded or secured to the assembly structure by metal mounting screw, with provisions for
penetrating the paint film. All electrical indicating instruments shall have square case, 96 mm side approx.,
unless otherwise stated elsewhere.

Field Indicating Instruments and Switches

Unless otherwise stated in the Technical Specifications, all the field indicating instruments and switches shall
follow the prescriptions given in this paragraph.

Thermometers

Thermometers shall be dial, liquid type. Their accuracy shall not be less than 1%.

The flexible pipe from the bulbs to the dial shall be one piece, stainless steel, compensated type, protected
against shocks, and shall be installed in such a way as to allow its removal as many times as desired without
interfering with other parts of the installation. The length from the bulbs to the dial should also be such to

Page 49 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
allow the location of the instrument where required. Thermometers may bear electric contacts for protection
or signaling. Dial diameter shall not be less than 100 mm.

Pressure Gauges

Pressure gauges shall have aluminum or brass case, with screwed pipe connections and stainless steel
movements, and shall be equipped with sectionalising and vent valves and suitable pressure pulsations
dampers. Their accuracy shall not be less than 1%. Each pressure gauge shall be equipped with zero
setting. Pressure gauges may bear electric contacts for protection or signaling. Dial diameter shall not be less
than 100 mm.

Thermostats

Thermostats shall be of thermal bulbs type and shall have two sets of contacts continuously and
independently adjustable within a suitable range, which in any case shall not be less than 40% of the rated
switch temperature. One set shall be used for alarm and the other for trip circuits. Contacts may be of
mercury or metal type.

Pressure Switches

Pressure switches shall be of the bellow type and shall have two sets of contacts continuously and
independently adjustable within a suitable range, which in any case shall not be less than 40% of the rated
switch pressure (applicable to direct or differentially sensed pressure). One set shall be used for alarm and
the other for trip circuit. Contacts may be mercury or metal type.

Tank Level Indicators

Tank level indicators shall be of direct readings, glass column type, protected against shocks and with house
casing. Connections shall be made by copper pipe with sectionalising valve. Check valves shall be fitted
on level indicators for pressurised reservoirs in order to avoid liquid loss in case of glass break.

Limit Switches

Limit switches shall be used for auxiliary circuits connection and disconnection. They shall be suitable for
outdoors installation and will have at least one make and one break contact. All the limit switches shall
operate at 110 V DC 10%, unless otherwise specified. They shall be heavy duty type and withstand at least
1 000 switching cycles per hour, under rated current conditions. Contact ratings shall have continuous
current carrying of 10 A and 1 A breaking capacity at 110 V DC, inductive load L/R = 20 ms.

The contacts shall be made of solid silver or of special alloy. Unless otherwise specified, all limit switches
shall be snap-acting type.

Remote Metering

Should any measure need to be transmitted, the Contractor shall supply the necessary primary element and
transducer, according to the following requirements.

All measuring equipment shall be fed at stabilised 230 V AC, unless otherwise specified elsewhere. In case
the measuring equipment require a voltage other than 230 V AC, the Sub-Contractor should provide adequate
power supply matching unit. The impulse lines between the primary elements and the transducer shall be
installed at a gradient so that no air pockets or water locks can occur. If the required gradient cannot be
achieved, water or air separators, drain or vent valves shall be installed. The primary elements shall be:

Temperature Measurement

Resistance Thermal Detectors (RTD) shall be used; they shall be standard type platinum 100 at 0C with
temperature coefficient 0.00385 K-1. The RTD protecting tube shall be of the screw-in type. Three wire
circuit shall be utilized for connecting the RTD to the measuring unit.

Level Measurement

Page 50 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The level measurement shall be made by means of a pressure sensor or by float. The error limits of the
measuring chain (primary element, transducer) shall not exceed 1%.

Should float and balance weight method be used, the float and the rope shall be of stainless steel. The level
primary measuring element shall have electric contacts, potential free, for min. and max. level signaling and
control.

Flow Measurement

The flow measurement shall be made by means of standard orifices or standard nozzles, or by other specified
methods, leading to a differential pressure measurement. Measurement shall start at a flow rate not higher
than 5% while the maximum flow shall correspond to 70-80% of full scale.

Transducers

The transducers shall be of the electronic type, with an output signal range of 4 to 20 mA DC, for single
direction flow and - 20 to + 20 mA for reversible flow. The rms ripple current shall be less than two (2)
percent. The output shall be limited to not more than 40 mA even though the input amplitude exceeds 200%
of the rated value. Each transducer shall be able to operate into a load impedance ranging between 0 and 1
000 , without adjustment of the output.

Each transducer shall be provided with a setting device for adjustment of the output current in the range of
10% to compensate for possible errors in the primary element. The output current shall be proportional to the
input, with an accuracy of 0.5% in the range from 5% to 125% of the full rated output. The transducers and
the relevant power supply network shall be so designed that no appreciable deviation in the output current is
produced by switching or other voltage transients in the supply. The output leads from the transducers to the
main terminal block shall be screened.

Treatment of Surfaces

General

The scope of these prescriptions is to establish materials and workmanship such as to ensure a first quality
and homogeneous work. Such prescriptions are summarized on a general painting schedule. The Contractor
shall forward to MoE its own painting schedule, made on the basis of the prescription of the present chapter.
The Contractor schedule shall include description of each part with relevant shop and site painting treatments
and an affidavit of compliance, stating that all materials and work will comply, or have complied, with the
applicable requirements of these Specifications. Parts to be painted, with relevant painting prescriptions, are
indicated in the painting schedule. The prescriptions shall be applied to all minor parts which are included in
the Supply even if not mentioned in the schedule. Surfaces of stainless steel, copper and copper alloys,
rubber, glass and surfaces to be embedded in concrete need not be painted, unless otherwise specified. Any
part of the Supply that shall have to undergo a special painting, will be specifically mentioned in the various
Sections of the Technical Specifications. Painting will be carried out in accordance with the instructions and
recommendations of the paint manufacturers, as approved by MoE. Any equipment that is not likely to be
damaged during erection shall be finish painted at the shop, while it shall be primed and top coated only,
whenever the erection shall be deemed to damage the paint. Such equipment shall be finish-painted (or
intermediate and finish-painted) at site by the Contractor, after erection has been completed. Shop painting
shall be protected against damages during transport by wooden pads or other suitable means. Nevertheless,
the Contractor shall furnish the paint for any touch up that will be required after the erection has been
completed. The paints to be supplied for the site painting shall not be less than one hundred and twenty
percent (120%) of the estimated required quantity.

Preparation of Surfaces

All surfaces required to be painted, either at the shop or at site, shall be thoroughly cleaned so as to remove,
even where access is difficult, any dirt and foreign matter and to obtain a smooth and dry surface. In the
preparation of metal surfaces, all welds, beads, blisters and any defect shall be smooth ground and pits and
dents compound filled to obtain a clean and smooth surface. Ferrous metals shall have all rust, dust and scale
removed by sand-blasting. Oily and greasy surfaces shall be cleaned using suitable solvents and dried with
Page 51 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
compressed air blows. In any case the state of surfaces shall be in accordance with the SSPC Standards
requirements. Non ferrous metals and galvanised steel shall be thoroughly cleaned by solvent, by washing
and/or brushing. All metallic machined surfaces and surfaces not required to be painted shall be covered with
a protective coating of wax or oil. Unassembled pins and bolts shall be oiled and wrapped with moisture
resistant paper or protected by other suitable means.

The interior surfaces of piping, valves and other parts that have to undergo hydraulic tests shall be painted
before such test, unless otherwise specified. All the protective coatings shall be effective against salt air in
the case of transport by sea and shall be easily removable, if required.

Paints and Painting Equipment

The Contractor shall submit at least three (3) probable suppliers of paint materials for MoE's approval. The
paints and the paint products shall be a standard type of a well-known manufacturer, and a reference list of
past performances in similar power plants shall be submitted to MoE by the Contractor. All paints used shall
be produced by the same manufacturer where possible and the Contractor shall however be responsible for
the choice of compatible coatings. Painting equipment shall conform to paint manufacturer's
recommendations. Materials shall be delivered to the site in the manufacturer sealed container, bearing the
manufacturer labels indicating type and grade of content.

Application of Paint - General Standards

The prime coat shall be applied immediately following blasting and cleaning, before any condensation might
occur on the prepared surface. No paints shall be applied over dust, grease, oil or other incompatible matter.
No paints shall be applied during rainy or foggy weather, when the air temperature is below 10C or above
40C or when the surface temperature is below 5C or above 50C, and when air relative humidity is over
80% or air temperature is less than 2.5C above the dew-point. Paints shall not be applied even if the above
conditions are forecast to prevail within one day from scheduled paint application. Enclosures and heating
shall be provided as necessary to prevent dust circulation, to achieve required temperature and to protect the
finished surfaces. The time schedule for successive coats of paint shall be such as to allow the first coat to
dry hard and to be in required state to receive the second coat. The colour of successive coats of paint must
be different to allow easy identification of the sequence of painting, for control purposes. The paint film must
adhere perfectly to the painted surface. The Contractor shall pay particular care in applying the prescribed
paint thickness even where access is difficult or over corners and edges. To comply with the prescriptions,
additional coats shall be applied by brush or by spray until a satisfactory result is achieved. Coating shall be
applied in a workmanlike manner, so that the finished surfaces shall appear free from drops, waves, laps,
bubbles, brush marks or other defects.

Zinc Plating

The zinc protective coat shall be applied by bath or electrolytic process. It shall be adherent, smooth and free
from discontinuity and imperfections, such as bubbles, porosity, cracks or other irregularities that may affect
the soundness of the protective layer. The plating thickness shall correspond to a minimum rate of 600 g/m2.
The adhesiveness of the protective layer shall be such as not to be removable during normal handling,
transport and assembly operations. After immersion in the molten zinc bath the protected surfaces shall not
be submitted to any process of scraping or wiping that may reduce the uniformity of the thickness of the
protective coat. Items plated by electrolytic process shall be dehydrogenated after plating.

Colours

The Contractor shall comply with the requirements of the Employer as far as identification colours are
concerned. MoE shall entrust, after the award of the Contract, a complete list of colours for the equipment
not covered by the Employer's requirements. The Contractor shall submit for approval to MoE painted
samples, 150 x 300 mm.

No paint shall be ordered until approval from the Main Owners Engineer has been given.

Page 52 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Inspection, Tests and Guarantees on Painting

The checks of the painting shall be carried out in the workshop and at Site, at the expenses of the Contractor,
in compliance with the following provisions:

a) Check of the material adopted;

b) Check of the sand-blasted surfaces;

c) Measurements of the thickness of the various paint coats and of the total paint coat, by means of a suitable
meter.

Should the measured Dry Film Thickness (DFT) be less than the specified, the Sub-Contractor shall apply
additional paint to the coat inspected or shall increase the thickness of succeeding coat, as applicable, to
assure the specified total dry film thickness. The guarantee period of the paintwork shall be five years,
beginning from acceptance of the paintwork itself. After this period the rusting level of coated surfaces shall
correspond to the Re O level, in accordance with the Rusting European Standard or equivalent. During this
period it shall remain the responsibility of the Contractor to repair or replace at its own expenses all
paintwork showing defects such as peeling, wrinkles, bubbles, flakes of rust, etc. where it may be shown that
the deterioration arises from poor quality paint, insufficient cleaning of the surface before painting, incorrect
choice of paint for the service required or incorrect application of paint itself to the surface. Gradual fading
of strong colours will be tolerated. The guarantee shall not cover any damage due to accidental causes.

Painting Schedule

The painting procedure, the number of coats to be used and the thickness of the applied layers shall be in
compliance with the following requirements, unless otherwise specified in the Technical Specifications.

Structural and Miscellaneous Steel (indoor and outdoor items except galvanised steel)

Near white metal sandblast SSPC-SP10

One coat of zinc filled inorganic silicate primer, Min DFT*) per coat 75 m

One coat of polyamide epoxy topcoat, Min DFT per coat 75 m

Steel Gratings & Chequered Plates

Hot dip galvanizing, Min rate 600 g/m2

Equipment

Exterior surfaces indoor & outdoor

Near white metal sandblast SSPC-SP10

One coat of zinc chromate catalyzed epoxy

primer, Min DFT per coat 75 m

Two coat of catalyzed epoxy enamel, Min DFT per coat: 75 m

Exterior surfaces underground

Near white metal sandblast SSPC-SP10

One coat of epoxy coaltar coating, Min DFT per coat 200 m

Two coat of epoxy coaltar finish, Min DFT per coat 200 m

Page 53 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Boards, panels, MCCs

Pickling, washing, phosphatizing

Two coats (three for exterior surfaces) of polyamide epoxy paint, Min DFT per coat 40 m

Electric motors and other standard equipment

As per Manufacturer's Standard

Piping (including hangers, supports & valves)

Exterior surfaces indoor/outdoor

Near white metal sandblast SSPC-SP10

One coat of zinc filled inorganic silicate primer, Min DFT per coat 75 m

One coat of polyamide epoxy topcoat, Min DFT per coat 125 m

Exterior surfaces underground

Near white metal sandblast SSPC-SP10

Two coats of epoxy coaltar coating, Min DFT per coat 200 m

Fresh Water Submerged or Intermittently Submerged Surfaces

White metal sandblast SSPC-SP5

Two coats of epoxy zinc rich coating, Min DFT per coat 35 m

Two coats of epoxy coaltar coating, Min DFT per coat 200 m

Surfaces in Contact with Oil

White metal sandblast SSPC-SP5

Two coats of glyptal base oil resistant coating, Min DFT per coat 20 m

Places of manufacture, testing and inspection


As soon as practicable after entering into the Contract, the Contractor shall furnish or provide to the Owner
Engineer the following:

A list of the workshop in which the different parts of equipment are manufactured;

All orders placed for materials and equipment purchased;

A list of all sub-orders placed, including order number, suppliers identity, equipment specifications,
delivery and dispatch dates, etc. ;

A test schedule for proposed dates of the manufacturers and the places of manufacture, testing and
inspection before shipment for the various portions of the Works.

Training
The Contractor shall provide training for the Owners operating and maintenance staff, and the cost of the
training courses and travel and living expenses shall be borne by the Contractor. The training scope shall be
based on [300] man days of off-site training with the following details.
Page 54 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
General
The Works shall include for separate training sessions for operating and for maintenance staff. Such training
shall be at the Contractors expense and to an agreed pre-scheduled programme. The level of training shall be
suitable for each member of staff to ensure individual competence in the operation, troubleshooting,
maintenance, administration and management of the Power Station. The Contractor will be responsible for
the planning and co-ordination of the training in conjunction with the Employer. A fully detailed training
programme with dates shall be submitted to MoE for approval [4] months after award of the Contract. The
training shall be ongoing during the testing and commissioning period so as to ensure that operating and
maintenance instructions have been given on all commissioned plant items handed over to the Owner.

The site training shall consist of programmes and scheduled training provided by the Contractor. Formal
classroom training supported by audio and/or visual aids and to a larger extent practical hand on exercises
with the equipment supplied under the Contract shall be part of the onsite training and shall cover:

a. Basics open cycle operation theory

plant descriptions

main components of the Works

b. Operation control system

operating procedures

start up/shutdown

full load/partial load

efficiency and heat balance

emergency operations

abnormal operations

c. Mechanical maintenance inspection tasks, planning

minor maintenance on mechanical


plant

d. Electrical maintenance inspection tasks, planning

minor maintenance work on the generator and


exciter

minor maintenance work on electrical equipment

minor maintenance work on instrumentation

2e. Trouble shooting main mechanical components generator and


electrical equipment control and protective relay
equipment

3f. Control and instrumentation

systems operation

maintenance and testing

Page 55 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
configuration

fault finding

Content of training
The training shall generally comprise a combination of formal instruction on site and/or at major equipment
manufacturers training facilities, and on the job hands on training and familiarization during the
construction, commissioning and initial operation periods on site. Where training at manufacturers works is
proposed the benefits of using such off site training facilities must be clearly identified by the Contractor.

The site training shall consist of training by the equipment manufacturers and/or by the Contractor, for
SIEMENS furnished and BOP equipment. Allowance shall be made for formal classroom training as part of
the on-site training. All formal training shall be carried out by dedicated training engineers who must be
familiar with the specific plant installation.

The Contractor shall make available qualified and experienced full time instructors competent in presenting
comprehensive courses covering the operating and maintenance of all items of the plant. Sufficient numbers
of the instructors shall be fluent in the English language to enable the training to proceed logically and be
fully beneficial. All training costs and expenses, training materials, manuals, and use of training facilities
costs shall be borne by the Contractor.

Operation of the plant during commissioning will be carried out by the station personnel, as far as possible,
under the control of the Contractors personnel who will retain at all times responsibility for commissioning
and operation of the plant. Hands on training and familiarization during commissioning shall include control
room and local control station operation, start-up, shut down, all design modes of operation, routine plant
changeover and test, routine maintenance and fault finding.

The staff shall partake in as detailed a study of the plant and equipment accessories systems, operating
procedures, maintenance requirements, O&M manuals and drawings as is necessary for the continuous, safe,
efficient and economic operation of the plant and shall receive theoretical and hands-on training on all of the
systems control, protection, operation and general plant specific troubleshooting procedures.

The training shall be directed at competent operations and maintenance staff who will ultimately operate
and carry out routine maintenance of the plant following take-over. The curriculum vitae for each supervisor
and instructor shall be submitted to MoE and Employer for approval before he is employed n the site. The
Bidder shall show in the Schedules the period, number and category of staff proposed for this service.

All training shall be programmed, scheduled and co-ordinated by a training specialist whose sole
responsibility will be to ensure that all the station staff have had sufficient technical training and on the job
training to operationally manage the station to the standards of a reasonable and prudent operator. The
programme shall include for recorded assessment of trainees, trainers, and the extent/adequacy of the
training programme. Assessment records shall be submitted to the Employer on completion of each training
module. Where the assessments indicate that the performance of the trainer and or adequacy of the content of
a training module is unsatisfactory the Contractor will be required to propose remedial action. Such action
will be at the Contractors expense.

Spare Parts
In addition, the Contractor shall submit with its Bid a detailed list of recommended spare parts and special
tools for the first (2) years of operation.

The Contractor shall also provide all the commissioning consumables and spares up to take over of the
works.

Page 56 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Special tools and lifting device
The Contractor shall provide with its Bid a list of any special tools and other equipment necessary for the
dismantling, work storage, re-erection and adjustment of any part of the plant. Tools shall be provided in new
condition, adequately labelled to their use and contained in stout and suitable padlocked boxes.

Any special lifting devices/slings required shall be provided and clearly marked by embossed labels which
show safe working loads. Test Certificates shall be provided where applicable.

Suitable lifting equipment shall be provided to facilitate removal and maintenance of plant and equipment.
Lifting devices shall be designed in accordance with the latest editions of the relevant ISO standard or
equivalent. All electrical and mechanical functions shall be tested before dispatch from the manufacturers
works. Operational and overload tests shall be carried out on site.

Suitable lay down areas and methods of retrieving the equipment should be included to support the
integrated approach to the crane facilities.

Warranty engineer
During the warranty period, the warranty engineer shall be available for callout and shall arrive at the site
within [eight] hours after receiving the notification. The warranty engineer shall have not less than eight
years experience of power plants similar to the Facility and shall act proactively to ensure the best
performance and availability of the plant is achieved. The travelling and living expenses for the Warranty
Engineer shall be borne by the Contractor.

The warranty engineering shall be responsible for the following throughout the warranty period:

a. Ensuring that the O&M operator is operating and maintaining the entire plant in accordance with the
manufacturers instructions, and notifying the Owner and the O&M operator of any shortcomings.

b. Providing technical advice and support to the O&M operator.

c. Monitoring the performance and availability of the plant.

d. Assisting with troubleshooting.

e. Acting as liaison with the Contractors head office for the clearance of any defects existing on Takeover
or occurring during the warranty period, to ensure that they are cleared promptly.

The Owner will monitor the performance of the warranty engineer. Should its performance be unsatisfactory,
the Contractor shall provide a replacement engineer to the satisfaction of the Owner.

Quality Control, Inspection and testing

General
The whole of plant covered by this Contract will be subject to inspection and test by MoE during
manufacture, erection and on completion. The Contractors costs associated with all tests and inspection shall
be borne by the Contractor.

The Contractor and appointed subcontractors and suppliers are required to comply with the minimum
requirements for quality assurance and quality control (inspection and tests) to be applied to goods and
services as detailed below.

The Contractor and its nominated subcontractors shall work to defined quality assurance programmes
compliant with ISO 9001. The Contractor shall list the quality level(s) proposed for its own, its

Page 57 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
subcontractor's and suppliers scope of supply. The Contractor shall supply the results of any recent audits
and approvals held.

The Contractor shall undertake in respect of its subcontractors, where no such acceptable information is
available or where the subcontractor has not been subject to an acceptable external quality audit within the
previous 12 months, the carrying out a quality audit of that subcontractor to ensure that completion of the
work will be compliant with the Contract requirements.

The Contractor shall have sole responsibility for ensuring compliance with the overall quality requirements
of the Works, and shall ensure that subcontractors implement those quality control activities that are
appropriate to the extent and nature of their supply.

The information supplied in response to the Quality Assurance requirements shall be deemed as part of the
quality assurance arrangement and when agreed and accepted by the Employer shall form an integral part of
the Contract.

The Contractor shall where required by the contract or other regulatory requirements appoint an approved
body to carry out an independent design, inspection and test audit.

The Contractor shall establish and maintain a documented inspection system capable of producing objective
evidence that all materials; manufactured parts and assemblies comply with the quality requirements of the
Contract.

The Contractor shall establish a written procedure to identify and disposition any deviations identified during
the course of manufacture, inspection and test etc.

The Contractor and its nominated subcontractors may be subject to quality audit by MoE.

The Contractor shall give all necessary help and assistance to MoE in carrying out such a quality assurance
review. Such audits may take place during the bid evaluation period

Extent of work
The Bidder shall define in the Schedule the items within its extent of work; those items to be sub-contracted
and propose the quality level attributed to each together with all items for which quality plans (inspection
and test plans) will be submitted. The Bidder shall identify the names and locations of the suppliers of all
materials, equipment and services including the locations of companies within its own group of companies.

a. The Contractor's quality system shall include as a minimum, procedures used for controlling the
following functions.

b. Inclusion on purchase orders of the necessary technical inspection and test details to meet the specified
requirements and of MoE's right of involvement at the Contractors, subcontractors and suppliers
works.

c. Availability at inspection points of applicable drawings, instructions, etc, and prompt removal of
superseded documents.

d. Maintenance and calibration of suitable inspection and test equipment.

e. Incoming, in process and final inspection and inspection of packing and marking.

f. Means of identifying inspection status throughout manufacture.

g. Means of identifying and isolating raw materials and components not conforming to the Contract.

Page 58 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
h. Provision of a written procedure to identify and disposition any requested deviations to the applicable
national standards and specifications mentioned in the contract specification. All such items shall be
reported to MoE via a non-conformance report.

i. Provision of complete inspection and test records.

Document submission
The Contractor shall submit for review, within 30 days of the Contract award a quality plan (inspection and
test plans) defining the programme of quality control and inspection activities which he or its
subcontractors/suppliers will perform in order to ensure that the procurement, manufacture and completion
of the materials, equipment and plant complies with the specified requirements.

All submitted documents shall clearly identify the manufacturer and the item/sub-item of plant to which they
apply.

The quality plan may be of any form to suit the Contractor's system, but it shall as a minimum:

a. Indicate each inspection and test point and its relative location in the production cycle including
incoming, packing and site inspections.

b. Indicate where subcontractors' services will be employed (e.g. subcontractor NDT or heat treatment).

c. Identify the characteristics to be inspected, examined, and tested at each point and reference drawings,
procedures and acceptance criteria to be used.

d. Indicate the inspection, test and hold points established by the supplier, subcontractor and Contractor,
which require verification of selected characteristics of a document, item or process before this
work can proceed.

e. Allow for witness, hold and review points to be established by MoE, which require its verification of
selected characteristics of a document, item or process before this work can proceed.

f. Define or refer to sampling plans if proposed and where they will be used.

g. Where applicable, specify where lots or batches will be used.

h. Relevant acceptance criteria.

MoE will indicate the inspection requirements on the agreed inspection programme in accordance with the
following:

i. Hold point requires a mandatory inspection by the Engineer. This inspection or test shall be witnessed
by the Engineer and further progress in manufacture shall not be made until the plant is approved by
MoE.

ii. Witness point inspection or test of material may be carried out by the Engineer at its discretion.

iii. Document review certification of material and functional test shall be approved by MoE before
dispatch from the works.

Independently, the requirements of the Third Party Inspectorate shall be indicated in a similar manner prior
to the submission of the Inspection Plan to MoE, for its approval.

The Contractor shall forward for Owners Engineer review within 60 days of contract award for applicable
items of equipment identified within quality plans, duplicate copies of:

Page 59 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
A. Special process procedures covering the welding, heat treatment and non-destructive examinations of all
pressure retaining and loading bearing fabrication welds and major castings including repair procedures.
Procedures must include qualification records and acceptance criteria where applicable.

B. Inspection procedures for components and test procedures for sub-assemblies and complete assembly of
the turbine shall be submitted to the Engineer for approval before assembly commences.

C. Test procedures for the witness testing of generators, excitation system, transformers, motors, frequency
converters, HV and MV cables, HV, MV, and LV switchgear, UPS and DC systems, protection
equipment and circuit breakers and frequency converters.

D. Test procedures for the witness testing central and local control panels, SCADA and DCS equipment

E. Test procedures for the witness testing pumps, compressors and automated valves.

F. Purchase orders (unpriced) complete with technical specification and data sheets.

Inspection notification and right of access


In order to verify compliance with engineering procurement, manufacturing requirements and programmes,
MoE shall have access at all reasonable times, to all places where materials or equipment are being prepared
or manufactured and tested, including the works of the Contractor, subcontractors or suppliers of raw
materials.

The Contractor shall advise MoE of the readiness of inspection at least 10 working days prior to a nominated
witness or hold point. Work shall not proceed beyond a hold point without the written agreement of the
Owner or its nominated representative. A common form of notification will be developed and agreed for
general use on the contract.

Before giving such notice the Contractor is required to have completed all its internal controls, including that
relative to the notification point and to have available documentation to that effect for MoE to review.

Request for waiver from contract quality requirements shall be made by the Contractor to MoE, as soon as it
is established that an item of equipment as designed, or in manufacture, cannot be made to comply with a
particular specified requirement. The subject item of equipment shall not be offered for final inspection until
such waiver requests have been approved by MoE.

Inspection and tests


Inspection of materials or equipment may be made by the Engineer and could include the following
activities:

a. Evaluation of the Contractor's system and approval of the quality plans.

b. Periodic monitoring to confirm the effectiveness of and the Contractor's, subcontractors and
suppliers compliance with the established quality system procedures, inspection and test plans and
inspection and test instructions.

c. Witnessing of inspections and tests and/or verification of inspection records to be carried


out at the Engineer's discretion covering:

d. Compliance of raw material with specified requirements

e. Compliance of manufactured parts, assemblies and final items with Specifications, drawings;
standards and good engineering practice.

Page 60 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
f. Periodic inspection of Contractor's design, manufacturing, installation work and the production
of progress reports.

g. Witnessing of inspections and tests.

h. Packing for shipment including check for completeness of shipment, handling requirements, and
case markings and identification.

The Contractor shall keep MoE informed in advance of the time of starting and of the progress of the work in
its various stages so that arrangements can be made for inspection and for test. The Contractor shall plan the
performance of inspection and tests so as to avoid the delaying of the work.

All of the required inspections and tests shall be made at the Contractor's expense, including the cost of all
samples used. The Contractor shall be responsible for any additional costs incurred by MoE arising from the
postponement, re-inspection or additional inspections or visits attributable to the Contractor, subcontractors
or suppliers performance. The Contractor shall also provide, without charge, all reasonable facilities and
assistance for the safety and convenience of the Owner Engineer in the performance of its duties.

If the plant or any portion thereof fails under test to give the required performance, such further tests which
are considered necessary by the Engineer shall be carried out by the Contractor and the whole cost of the
repeated tests shall be borne by the Contractor. This also applies to tests carried out at subcontractors works.

Non-conformances
Non-conformances identified by MoE shall be notified to the Contractor by issue of MoEs Non-
Conformance Report. The Contractor shall receive and action all non-conformance reports and re-inspection
shall not be notified until the completed non-conformance report, together with any applicable re-work or
concession application, have been accepted by MoE.

Where applicable, rejection of materials, equipment and/or components will be made as promptly as
practicable following any inspection or test involvement by MoE. Failure to inspect and or reject materials,
equipment and/or components shall neither relieve the Contractor from responsibility for such items which
may not be in accordance with the specified requirements, nor impose liability for them on MoE.

The Contractor and subcontractors quality assurance programme shall identify and isolate raw materials and
components not conforming to the Design Book. All such items shall be reported to the Owner via a non-
conformance report.

Approval of a concession application is the prerogative of MoE and approval of a particular case shall not set
precedent.

MoE shall have complete authority to accept or reject any equipment or part thereof considered
unsatisfactory not in accordance with the contract requirements.

The witness of any inspection and tests by MoE of any components or lots thereof does not relieve the
Contractor of any responsibility whatever regarding defects or other failures which may be found before the
end of the warranty period

Quality control records, certificates and certificates of conformance


At the end of each visit to a manufacturer to carry out quality control activity, MoEs Representative will
complete a Quality Control Record and hand one copy to a responsible representative of the Manufacturer.

The Quality Control Record (QCR) will identify the item inspected, the stage of manufacture, and the nature
of the QC carried out, and will list all points which require remedial action by the manufacturer, before the
subject item can be released.

Page 61 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
When each item of equipment is ready for dispatch from the place of manufacture and MoE has verified
compliance with specified requirements up to that point, a Quality Control Certificate will be issued to the
Contractor.

The Quality Control Certificate (QCC) will identify the item to which it applies and will release that item
from MoEs control only. The QCC does not constitute any form of acceptance of the item by either MoE or
the Employer.

The Contractor shall provide a Certificate of Conformance confirming compliance with the Contract
requirements and as detailed in the manufacturing record data book.

Sets of all test records, test certificates and performance curves, whether or not they have been witnessed by
MoE, shall be supplied for all tests carried out in accordance with the provisions of this Contract.

Sets of all test certificates shall be endorsed with sufficient information to identify the material or equipment
to which the certificates refer, and shall carry in the top right hand corner the following reference:

Owners name

Project title

Owners Engineers reference number.

All test documentation shall be in the English language.

No materials or equipment shall be shipped to the Site until all tests, analysis and inspections have been
made and the Contractor's Certificate of Conformance has been reviewed and released by the Engineer; or
unless otherwise agreed by MoE.

Specific tests and inspections


Refer to Chapter 3 for details of specific tests and inspections

Meetings

Meetings during design phase


A project progress meeting shall be convened with the Contractor, the Owner and any other participants that
the Owner deems necessary within five (5) calendar days after the submission of each monthly project
progress report, at locations to be determined later.

If these reviews demonstrate that the Contractors or Vendors design is not adequate, the Contractor will be
requested to take immediate correctives actions to correct the proposed design. During the initial kick off
meeting the list of items for review will be discussed and reviews dates scheduled based on the Project
schedule considering the Contractor's engineering, procurement and equipments shipping schedule.

The Owner shall have the right to convene an extraordinary project progress meeting at any time that the
Owner deems a construction issue or problem requires such a meeting.

Meetings during construction phase


Description

The Owner or the Owner Engineer will schedule and administer all construction meetings at the jobsite
involving interface between any two or more of the major parties, including the Owner Representative, , the
Contractors Construction Manager.

Page 62 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Contractor shall be represented by Contractors Construction Manager and Construction Superintendent
at all meetings requiring the presence of the Contractor, unless otherwise specified. The Contractors
Construction Manager must designate a representative for prior approval by MoE if unable to attend a
meeting where its presence has been requested.

Pre-construction Meeting

A pre-construction meeting will be scheduled to be held as directed by the Owner Representative or Owners
Engineer.

Attendance - The Contractor shall have in attendance at the meeting, as a minimum, key project personnel
who shall be responsible in the performance of construction management, labor management, contract
administration, safety management, quality assurance/control, scheduling, cost control, and material control
as well as representatives of major subcontractors. Items to be discussed:

a. Introductions
b. Responsibilities of Contractors, Owner Representative, Owners Engineer
and Owners Engineer Key Project Personnel
c. Project Administration
d. Site Conditions and Requirements
e. Material Receipt
f. Commercial Submittals
g. Technical Submittals
h. Project Schedule
i. Progress Reporting
j. Invoicing and Payments
k. Additional Work Request and Change Order Procedures
l. Quality Assurance / Control Program
m. Environmental / Hazardous Waste
n. Contractors Safety Program
o. Site Safety Orientation
p. Contract Close-out

Weekly progress meetings

Once construction has commenced at the job site, meetings will be held weekly. Key representatives or
designees from the Contractor, Owner or Owners Engineer will attend .

The Agenda at the regular progress meeting shall include:

a. Review minutes of previous meeting.


b. Review administrative items.
c. Review status of submittals.
d. Review material deliveries.
e. Review status of construction schedule.
f. Review progress and productivity reports.
g. Work progress planned during next work period and its effect on related work of others.
h. Review and note field observations, problems, and decisions .

The Contractors Construction Manager will make physical arrangements for the meetings, prepare agenda
with copies for participants, preside over the meetings, record the minutes of the meetings, and distribute
copies within three work days to the participants and those affected by the decisions made at the meetings.

Page 63 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Start-up coordination meetings

These meetings will be convened at the project site as the project converts from production installation by
work area to completion by system (normally when installation is around 65%-70% complete). The purpose
of these meetings will be to coordinate the various aspects of plant startup including system completion,
construction testing, punchlist work, commissioning, operations staffing, training, system turnover, startup
and commercial operation. In general, these meetings will be attended by the Owner and/ or Owners
Engineer, Contractors Construction Manager, Equipment Suppliers (as required), Plant Operations, as
appropriate.

Initially these meetings will be held weekly, replacing part or all of the weekly progress meetings outlined
above. As construction completion nears, and the work begins to concentrate around punchlist completion
and commissioning of equipment, the meetings will be held daily at the commencement of the days
activities to ensure coordination of the effort and for safety awareness.

The Agenda at the Startup Meeting shall include:

System Completion Status (bulk installation)


Punchlist Status
Schedule of near term activities
Safety requirements
Technical assistance or vendor support requirements
Special equipment or tools
Utility requirements
Instrumentation Control Status and Requirements
Contractor labor support
Operation interface

Special meeting

Meetings other than the regularly scheduled progress meetings may be called by the Owner Representative
or Owner' or requested by the Contractor to review special issues. These meetings shall be attended by the
entities directly affected by the purpose of the meeting. Examples of such meetings are:

Special Rigging or Hauling Meeting


Gas Turbine Generator Material Receipt and Erection Meeting

Construction control requirement

4.22.1 General
The Contractor will be required to provide information and data in the form of a Contract Schedule and an
Earned Value Reports for the work in accordance with the requirements of the Project Plan developed by the
Contractor and approved by the Owner Engineer.

The Contractor must agree to the Milestones presented in the General Contract schedule. Any proposed
changes to these Milestones must be presented to the Owner Engineer for review and concurrence prior to
incorporation into any Contract Schedule. As well, any proposed changes in scheduled activities that impact
the completion Milestones and/or delivery of materials to the project site must be reviewed and approved by
the Owner Engineer prior to inclusion in the Contract Schedule.
Page 64 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Contractor shall arrange the Work of the project Schedule to conform to the requirements of the
Drawings and Specifications in order to complete the Work within the time specified or as extended only by
written approval of MoE. It shall be the Contractor's responsibility to check with Owners Engineer
concerning actual progress of other work being carried out, and to schedule the arrival of its materials,
equipment and labor at the site so as to properly coordinate its work with the work of other Contractors.
There will be no extra compensation for work, which the Contractor must perform, due to its failure to
coordinate its work with the work and the work of other Contractors.

4.22.2 Project schedule


The project schedule format and preparation shall comply with the requirements specified in the General and
Particular Conditions included in the contract .

Guidelines and Instructions

Within fourteen calendar days (14) after Purchase Order, the Contractor shall submit a Baseline Schedule
Outline in accordance with the Work Breakdown Structure (WBS) included in the Bid Documents. MoE will
review the Baseline Schedule Outline for clarity and level of detail. MoE will provide comments to
Contractor within ten calendar days (10).
The Contractor shall utilise the Baseline Schedule in developing the 120 days look ahead schedule and shall
submit it once a month to Owners Engineer.

4.22.3 Progress updated

The Contract Schedule is to be updated on a weekly basis throughout the duration of the Work until contract
completion. The Contractor shall meet with Owner Representative and Owners Engineer at the Weekly
Progress and Coordination Meeting to review actual progress made through the date of the Contract
Schedule update, including dates for activities actually started and/or completed, and to review the overall
percentage of Work actually completed.

Each Contract Schedule update shall be transmitted Owner and Owners Engineer two (2) days prior to the
Weekly Progress and Coordination Meeting.

In addition to the Contract Schedule updates, the Contractor shall submit a Monthly Contractors Report
containing the following minimum information:

Monthly Contractors Progress Report

Timing: Submit 1 Soft copies and 2 Hard copies the 7th of each calendar month.

Contractor Name:

Reporting Month:

Management Summary (One Page)

Overall Project Situation


Major Activity
Significant Problems
Activities Planned for Following Month
Page 65 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

Narrative

Discussion of schedule logic for activities starting next 30 days


Outlook for potential schedule delays or conflicts for activities
outside of Critical Path

Progress Review

Updated Bar Chart Schedule (Current vs. Baseline)


Milestone Report
Procurement, Construction & Overall S-Curve - Planned vs.
Earned vs. % Budget Man-Hours Expended (Cumulative &
Incremental)
Problems Affecting Progress
Decisions and Actions

Manpower and Productivity Analysis

Planned and Current Manpower


Productivity to Date - Actual vs. Earned (Cumulative &
Incremental)
Manpower Projection to Complete

Commercial Status

Payment Status
Change Order Register
Notice of Disputes

Quality Assurance

Safety and Security

4.22.4 Cost control


The purpose is to provide a method to ensure the accuracy and validity of tracked budgeted costs, committed
costs and actual costs. Cost information/reports will be issued daily, weekly and monthly as PART of the
Monthly Status Report.

The Contractor is to report Earned Value in terms of:

-Scheduled, or planned man-hours (budget man-hours)

-Earned man-hours

-Actual man-hours

Man-hours are to be defined as direct hands-on craft man-hours up to the level of General Foreman.
Indirect, maintenance or supervisory man-hours are not to be included.

The Contractor shall meet with the Owner Representative and Owners Engineer within seven (7) days after
ATP to assure mutual understanding of these requirements.

4.22.5 Guideline and instruction

Cost Reporting Weekly


Page 66 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Contractor shall prepare the following reports:

a. Weekly Summary Report of weekly quantities of material installed (sorted by system /


discipline, by craft).

b. Weekly field staff & craft labor manpower forecasts for the contractor and subcontractors.
(Sorted by system / discipline, by craft).

Weekly Progress Reports will be in tabular and graphic format. Contractor to submit hard copy and
electronic documents.

Reports shall include the following information:

a. Total estimated quantities.

b. Total estimated craft man-hours.

c. Total estimated man-hours per estimated unit quantity.

d. Actual quantity completed this week.

e. Actual quantity completed to date.

f. Actual man-hours used this week.

g. Actual man-hours used to date.

h. Actual man-hours per unit quantity completed this week.

i. Actual man-hour per unit quantity completed to date.

j. Performance Ratio: Weekly and Cumulative.

k. Unit Man-Hour Exception Report: Listing of those systems being 15% completed and
having a cumulative performance ratio of 0.8 or less.

l. Weekly Progress Curve: This curve will provide planned versus actual weighted progress
(Weekly and Cumulative) (S-curve) vs. scheduled progress and % Budget Man-hours
Expended. Chart at the bottom of the curve should indicate weekly and cumulative
Schedule Performance Index (Actual % Complete vs. Budgeted % Complete).

m. Corrective Action Report: recovery plan (as required).

n. Projected Final Cost: (includes pending changes).

4.22.6 Guideline and instruction

The Contractor shall prepare summary reports for inclusion in the Monthly Status Report.

a. Cost and billing information by contract.

b. Monthly Percent Complete.

c. Corrective Action Report recovery plan (as required).

d. Contract Status Summary.

Page 67 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Construction inspection & monitoring program

22.1 General
EXTENT

This paragraph defines the requirements for the Construction Inspection & Monitoring Program (Program).
The intention of this Program is to provide the minimum requirements to ensure the project design is
implemented with high quality and that the construction is in compliance with all applicable specifications,
drawings and contract requirements.

The Contractor has the responsibility to ensure that all aspects of work comprising any activity during
construction is performed in accordance with the Projects design requirements, specifications, drawings,
codes and standards and contract requirements.

CONSTRUCTION INSPECTORS AND QUALIFICATIONS

The Contractor shall employ full time Inspectors qualified and knowledgeable in the specific discipline to
inspect and monitor construction. The Contractor shall provide the qualifications of the proposed inspectors
prior to commencement of work.

DOCUMENTATION

The Contractor shall submit documentation to demonstrate conformance with the requirements of the
Contract documents.

CONSTRUCTION CHECK LISTS

The Contractor shall complete construction checklists and forms to verify that its inspections are complete
and the work is in conformance with the design requirements.

WITNESS POINTS

Witness points may be required by MoE. The Contractor shall provide three (3) working days prior notice in
advance of performance of the test or inspection. Once notice has been given, the Contractor may proceed
with the test or inspection in the absence of the MOE or MOE Designee.

HOLD POINTS

Hold points may be required by the Owner Representative or Owner Engineer. The Contractor shall provide
three (3) working days prior notice to in advance of performance of the test or inspection.

Unless a waiver has been granted, the test or inspection may be rejected if the Owner Representative or
Owners Engineer has not witnessed the test or inspection. The Contractor may be directed, at its expense, to
repeat the test or inspection and to perform any work necessary or required to restore the work to its pre-test
state.

ACCESS

The Contractor shall provide the Owner and Owners Engineer full access to all of the Contractors work
areas and equipment associated with performance of the contract work.

22.2 Areas of inspection


PROGRAM REQUIREMENTS

Page 68 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The following sections delineate the areas of inspection and the minimum documentation required to be
submitted by the Contractor to demonstrate compliance with the Program.
The Contractor shall include, as part of the contract bid submittal, sample documents / forms that shall be
proposed for use in conjunction with the Program documentation requirements. Prior to commencement of
any work, the Contractor shall meet with Owner Representative or Owners Engineer to review the
documents / forms and Program requirements to ensure that all attributes of the Program are understood and
included in the Contractors scope of responsibility.

MATERIAL RECEIVING REPORT

The Contractor shall inspect material at the time of receipt. The receipt inspection shall be documented on a
Material Receiving Report (MRR). The report reflects the status of materials, components or equipment
received at the site.
The MRR shall have a unique number and shall identify the Vendor, Purchase Order (P.O.) number and the
P.O. originator. The MRR shall list each item and tag number (as appropriate), quantity etc. received in the
delivery.
When completed, the MRR along with the packing list shall be transmitted to Owner and Owner Engineer
so that payment can be authorized.

RECEIPT INSPECTION

The receipt inspection shall include as a minimum the following attributes:


Review of the packing list for correct entries for quantity and traceability of the items received.
Visual examination to verify the items have no physical damage caused by, but not limited to the
following:
a. Rough handling and shipping.
b. Failure of packaging, protective covers and seals.
c. Loss of inert gas blanketing or missing desiccant.

Spot checks and random verification of critical dimensions to ensure that overall
dimensions, mounting holes, weld end preparations, flange connections, configuration and
orientation conform to the requirements of the design documents.
General visual examination to determine that workmanship, materials, welding,
machining and painting conform to the design documents.
Marking and identification conform to the specified requirements as:
a. Material marking: heat numbers, piece marking, etc.
b. Nameplates: code stamping, manufacturings name, serial number, model number, etc.
c. Tags: purchase order, mark number, lettering size, etc.
d. Documentation: traceability to item, legibility, completeness, etc.

22.3 Material deficiencies


Deficiencies in materials delivered identified at the time of receipt inspection shall be documented on a
MATERIAL DEFICIENCY REPORT and forwarded to Owner and Owners Engineer for resolution.

22.4 Material receiving instruction


Certain material, equipment or hardware may require special handling and / or inspection. The Owner or
Owners Engineer may issue Material Receiving Instructions (MRI) to the Contractor for execution at time
of receipt. The instructions shall delineate those unique, additional or unusual attributes that may necessary.
Page 69 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Examples of attributes that may be included on the MRI are:
Receiving requirements.
Storage requirements
Maintenance requirements
Documentation required:
a. Certified Mill Test Reports
b. Non-destructive Test Reports
c. Certificates of Compliance
d. Maintenance Manual
e. Performance Test Reports
f. Code Data Report
g. Impact Tests

22.5 Material deficiency report


Deficiencies in materials delivered identified at the time of receipt inspection shall be documented on a
MATERIAL DEFICIENCY REPORT (MDR). Deficiency here is meant to mean: over / under count,
shortages, damage in transit etc. The Contractor shall identify the deficiency, damage, loss or unsatisfactory
condition of any material or equipment and forward the Owner and Owners Engineer for resolution. Non-
conforming conditions shall be documented on a Non-conformance Report . Non-conforming material shall
be tagged and segregated to ensure non-use.

22.6 Storage yard inspection report


The Contractor shall periodically conduct inspections / surveillances of the storage yards and laydown areas
to ensure material is properly stored and protected. The Contractor shall document the findings on a
STORAGE YARD INSPECTION REPORT. Inspection of indoor storage areas shall be included.
Examples of attributes that should be included / verified in the inspections are:

24-hour guard service is provided.


Materials are properly cribbed and stacked to prevent sagging.
Materials are properly covered where required.
Damaged materials are tagged and segregated.
Erosion is properly maintained.
Site is clean and free of trash and debris.
Combustible materials are isolated as required and safety regulations
are in force.

Equipment storage heaters are energized as required.


Desiccant are maintained
Inert gas blankets are maintained.
Conduct of periodic maintenance such as lubrication and rotation of
motors and pumps.

Material is adequately tagged or identified.


Piping end covers are in place.
Flange faces are protected.
Page 70 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011

22.7 Contractor responsibility


The Contractor shall forward copies of all Storage Yard Inspection Reports to Owner and Owners Engineer.
The Contractor is responsible to promptly correct all unsatisfactory conditions identified.

22.8 Non-conformance report


A Non-Conformance Report (NCR) shall be written for conditions that do not conform to design
specifications, drawings or procedures. It shall be written when an item, material, procedure, documentation
or installation is identified that could affect reliability or renders the item or activity unacceptable or
indeterminate.
Any responsible party can write an NCR. It shall describe the condition that is non-conforming and identify
the drawing, specification or procedure, code or standard etc. to which the condition does not conform. A
proposed disposition / corrective action may be included on the NCR.

22.9 Contractor responsibility


When the Contractor becomes aware that an item, material, procedure, documentation or installation does
not conform to engineering specifications or drawings, and it cannot be remedied in present time, he shall
originate an NCR to document the condition and for the purpose of ensuring resolution.
The original NCR shall be formally transmitted to Owner and Owners Engineer. A copy of all NCRs shall
be simultaneously forwarded to the Owner and Owners Engineer Site Representative.

22.10 Disposition
Owner and/or Owners Engineer will provide a disposition for the non-conformance along with any re-
inspections and / or tests required. The following categories shall be used to provide a disposition or
corrective action:
REJECT: A condition where the item or material is unsuitable for its intended use and requires
replacement/scrapping of the item or material.
REPAIR: A condition where the item or material can be made suitable for its intended use, but it shall
not meet all the design or functional requirements.
ACCEPT AS IS: A condition where the item or material shall satisfy its intended use, but it shall not
meet all the design or functional requirements.
REWORK: A condition where the item or material can be brought back into compliance with all design
and functional requirements.

22.11 Review approval


The Owner or Owners Engineer shall review all dispositions for NCRs prior to implementation .

22.12 Non-conformance report log


MoE shall maintain a log and copies of all NCRs. The log shall include as a minimum:
a. Sequential number.
b. Item or material that is non-conforming.
c. Date of issue.
d. Name and firm of initiator.
e. Date of completion of disposition.

Page 71 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
22.13 Completed non-conformance reports
Once completed, the original NCR along with any required test reports, shall be forwarded to the Owner and
Owners Engineer. The NCR shall be closed out in the NCR Report Log.
All NCRs shall be closed before any system is accepted as Construction Complete.

22.14 Stop work order


Failure by the Contractor to correct a non-conforming activity or procedure may result in a Stop Work Order
to be issued by the Owner or Owners Engineer. Work shall not proceed until the issue is resolved.
Expenses encountered due to the Stop Work Order shall be the responsibility of the Contractor.

22.15 Construction checklist


The Contractor shall utilize Construction Checklists to document the time the work is performed and
inspected. Construction Checklists reflect significant inspection points, but shall not relieve the Contractor
of its responsibility to comply with the design drawings and specifications.
Construction checklists are to be maintained by the Contractor and shall be made available to the Owner and
Owners Engineer for examination. The checklist shall be formally submitted during turnover at the
construction completion phase of the project.

Commissioning, Start-Up, and Tests On Completion

Plant startup program


This chapter describes general conditions for pre- commissioning, commissioning, start-up and testing of the
plant for operation.

The Contractor shall be responsible for the management and technical lead of the systems pre-
commissioning, functional testing, and turnover from construction to Plant Operations. Contractor shall
provide all tools, equipment, supplies, labor, management, technicians, and engineering support required to
complete the work.

The pre-commissioning, commissioning, and startup program provides sufficient technical control to ensure
the facilitys system (and components), which are part of or affected by the work, are thoroughly checked
and tested to the extent necessary to verify that the facility contractually is ready for startup, and that the
facility will run satisfactorily when the Work is placed in service.

Contractor is responsible to complete all installations of equipment, commodities, and other items necessary
for the safe operation of the facility to the specification and quality as indicated in the engineering
documents. The Contractor is responsible for testing his portion of the facility installation as indicated in the
requirements of the Contract and included specifications and providing the required documentation of these
tests for verification and record by the Owner.

The Contractor remains responsible for care, custody, and control of all equipment and systems until turned
over in writing with the appropriate documentation to the Owner and Owners Engineer and accepted by the
designated authorized Owners Engineer representative.

4.24.2 Pre-commissioning
Pre-commissioning, the first phase of the Plant Startup Program, consists of checks, calibrations,
adjustments, and tests to determine the physical completeness of a system, or component, as well as the
integrity of a completed piece (pipe or wire system).

Page 72 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Startup Program will define in detail such matters as the component testing and calibration program,
turnover procedure, tagging procedures, safety tagging and clearance procedures, testing field reports, and a
punchlist tracking procedure.

The Contractor shall be responsible for the documented execution of all pre-commissioning activities. These activities
include but are not limited to:

Electrical ISO Phase Bus Ducts


Mechanical
Equipment installed in Equipment is Grounded Properly and Bus Duct Installed Correctly /
accordance with P&ID Rat Guarded. Heaters On.

Skids Anchored Properly. Motor / Cables are Meggered, Hipotted, Bus Ducts Supported Correctly.
Glanded and Sealed

Pipes Supported Properly Phase Rotation has been Checked. Bus Duct Covers Installed
(include hanger details). (Static Test / Phase Rotation Meter).

Equipment Properly tagged Motor Runs Completed. Bus Ducts Air Tested (Where
and Identified. Applicable).

Valves Properly Tagged and Cable / Wire Properly Tagged. Bus Ducts Meggered.
Identified.

Hydrostatic Pressure Test Cable / Wire Terminations Verified Bus Ducts Properly Grounded
Complete Correct (Rung Out)

All System Cleaning / Conduits Properly installed and Bus Duct Terminations Tested
Flushing Complete. Supported Covers installed and
Properly Tagged.

Orifice Plates Correct and Cable Trays Properly Installed, Bus Duct Heaters Operating.
Installed Supported, Grounded, and Properly
Tagged.

Temporary Screens / Conduit Seals Installed and proved as As Built / As Installed Dwgs.
Strainers Installed required. Class 1 Div. 2

Welding QA/QC Records Junction Boxes Correctly Installed, Instrumentation


Complete as required. Properly Tagged, and Penetrations
Sealed.

Equipment Lubricated as MCCs / Switchgear Labelled Correctly. Instruments are tagged correctly.
required.

Equipment is clean / Remote Start / Stop Stations Labelled Instrument Wiring is Terminated
inspected and Ready for Correctly. Properly.
commissioning.

Motor Alignments All Control Panels Labelled Correctly. Dry Electrical Loop and Control
Completed. Checks /Ground Checks

Coupling Guards Installed Switches Installed Properly Instrument Process Tubing is


Installed Correctly.

Safety Equipment Proper Transformers Installed Properly per Instrument Covers are Installed
Installation Verified Manufacturers Recommendations.

Equipment Run-in / Surge Arrestors Installed and Tested. Instruments are Calibrated

Page 73 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Vibration Test. (Stickers Attached).

Grouting Verified Ground Grid Tested (Prior to Operation Heat Trace Complete
of Equipment)

As Built / As Installed Enclosures and Foundation Openings As Built / As Installed Drawings


Drawings Available. are Cleaned and Sealed. Available.

Piping insulation / Heat Indicating Lamps Installed Area Clean


Trace Cmpleted

Equipment Accessible Test Power transformers and Electrical


Equipment Complete

Area Clean Protective Solid State Relays


Calibrated.

As Built / As Installed Drawings


Available.

Area Clean

Note: Contractor responsible to maintain Redline Drawings through completion of the project.

Prior to commencement of testing, the equipment, piping, electrical, and instrumentation work will be
broken down into operational systems. The Contractors Startup Manager shall delineate the system
boundaries on marked-up P&IDs and electrical schematics for use during the Contractors testing. The
Startup Manager will also develop a System Turnover Schedule identifying when each of the operational
systems MUST be available for turnover to the Owner or Owners Engineer in order to support the plant
startup and performance testing schedule. The Contractor shall restructure its work plans to complete entire
operational systems in all disciplines of the scope (civil, mechanical, structural, electrical, and
instrumentation) including construction testing, so that each system is turned over to the Owner or Owner
Designee in a logical sequence for startup.

The Contractor shall provide a detailed schedule for the testing activities well in advance of commencing the
testing phase. The Contractor is responsible for the supply and coordination of all necessary advisory and
consulting service representatives of all suppliers and subcontractors within its scope of supply, including the
identification of incorrect installations, suggestions as to the method of operation, and expediting of
replacing materials.

When a systems components are installed, but prior to construction testing, a punch list walk down is
scheduled to identify and deficiencies between the engineered system and actual installation. To avoid
countless iterations of this process and to ensure that most items are captured initially, these walk downs will
be scheduled in the start-up meetings with the concurrence and participation of all interested parties.

The punchlists should be compiled by system in a standard format pre-approved by the Startup Manager.
The information should contain as a minimum:

System Name
Punch List Date
Item Number
Item Designation (Tag #, Line #, Equipment #)
Item Description
Responsible Party (Company Name)
Required for Test (Y/N)
Required for S/U (Y/N)
Target Completion Date

Page 74 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Actual Completion Date
By: (Name or Initials)
Verified Complete (CM QA/QC Initials)
Remarks

The punchlists will be updated as items are completed, being signed off first by the Contractor as complete,
and then amended with a Verified Complete signature by the Owner or Owner Designees Quality
Assurance representative.

No item shall be removed from the punchlist or signed off as completed or rectified without the confirming
inspection and authorized signature from the Owner or Owner Designee.

The punchlists will be reviewed weekly or more often as dictated by the frequency of the Startup Meetings
where these lists will serve as discussion points. The punchlists may be amended as items arise during the
continued progress on the completion, testing, turnover and commissioning of the system.

When the Required for Test items are completed and verified by the Owner or Owner Designees QA/QC
representative, the system components are considered ready for test.

The Contractor is responsible for all labor, equipment, and materials required to complete the tests as
specified in the engineering documents. Contractor is also responsible for completing all data sheets, logs,
and records as required including the appropriate witness verification signatures in preparation for system
turnover packages being transferred to the Owner or Owner Designee. The Contractor will be responsible
for maintaining the records for all testing throughout the construction phase of the project. He will also be
responsible for assembling all documentation for the turnover packages.

To ensure the safety of personnel and equipment, the Contractor shall install, calibrate, and perform
functional tests of all instrumentation, interlocks and safety circuitry prior to turnover.

The Contractor shall be responsible for the administration and management of the Safety and
Lockout/Tagout Procedures during the construction and pre-commissioning phase of the plant installation.
In support of this program, the Contractor shall assign a designated qualified Safety Officer(s) and support
personnel. Plant Operations personnel will be required to comply with the Contractors tagging procedure as
long as systems are under its jurisdiction.

During the transition from bulk construction to system completion and prior to the commencement of
startup, the Contractor will be provided with a complete schedule of greases and lubricants required for all
permanent plant equipment. The Contractor shall supply and install the first charge of all greases and
lubricants for this equipment.

At the conclusion of the testing, the system is reviewed for the completion of the Required for Startup
items. Upon completion of the Required for Start-Up items, the system is considered Substantially
Complete and can be considered for turn over to the Contractors Startup Manager for commissioning.

Substantial Completion shall be defined to mean that the Work, facility, or component thereof is ready for the
safe pre-operational check-out and startup for the purpose for which it was intended, all critical safety items
identified during the punchlist walkdown have been resolved, and only minor items remain to be completed
or corrected that would either not affect the operation as intended, or could be completed prior to the date of
pre-operational check-out and startup activities.

Page 75 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
4.1.1 Commissioning
Commissioning procedure

[6] months prior to the start of commissioning, the Contractor shall submit for review a site commissioning
record system that provides for all commissioning procedure and activities that shall be performed during the
work to be identified and readily traceable.

Each commissioning procedure shall include the following information as a minimum:

a. Objective and procedure

b. Scope of procedure

c. Reference documents, P&IDs and drawings

d. Prerequisites to the commissioning

e. List of relevant check

f. Check sheets with sections for signing off by construction, commissioning, and Owners
Engineer

Where check sheets include items such checking of alignment, vibration etc. Then the reference documents
shall clearly indicate the criteria against these parameters can be accepted. Vendor documentation is
acceptable for this purpose but must be adequately referenced on the check sheet and available.

A specific check sheet shall be provided for each component to be commissioned.

Packages of documentation shall be issued for each system of the work as they become mechanically
complete.

The records shall be sufficiently detailed to show all checks performed on systems, items of plant,
instrumentation and controls, and protection. It is envisaged they will cover all checks carried out prior to
equipment and systems being put into services and all functionality test thereafter.

The Contractor shall prepare maintain and updated a Punch list of all items which are incomplete or
defective and which require remedial action.

The Contractor shall prepare a detailed test and commissioning programme for issue to appropriate parties on
regular basis to illustrate commissioning progress against planned complete dates.

The Contractor shall establish a safety and permit-to-work system for the Site to ensure that the plant is
placed into and taken out of service in a safe and controlled manner so that the integrity of adjacent
construction work can be undertaken in a safe manner.

Commissioning

The Contractor shall be responsible for carrying out all the commissioning work associated with bringing the
plant to a condition where it is ready to undergo its reliability and performance tests.

Prior to the start of commissioning, the Contractor shall ensure that the owner's Engineer has been provided
with the latest edition of all relevant documents and drawings.

Once the component or system is charged, energized or otherwise made live, the Contractor shall conduct
further tests to demonstrate that the system and its constituent components function collectively as designed,
that individual components operate at varying loads under steady state conditions within their stated
operating parameters, and that the components and system respond correctly to transient conditions. The
Page 76 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
Contractor shall undertake whatever adjustments are necessary to achieve the best level of plant reliability,
capacity and performance.

In addition to the above, the following tests shall be carried out:

a. Fuel systems

All fuel supply systems shall be tested to demonstrate satisfactory fuel pressure and flow control under
all operating conditions including start-up, shutdown and full load rejection. This applies to both the
fuel gas and fuel oil systems.

b. Control function tests

When the Contractor has completed all commissioning of all the local and remote/supervisory control
functions, every function shall be demonstrated to have been commissioned, calibrated and loop tested.
Tests to verify the correct and safe operation of the plant will also be conducted to a protocol agreed
between the Contractor and the Engineer.

c. Load rejection test

It shall be demonstrated that the instantaneous rejection of full load from the gas turbine will not cause
an overspeed trip of the unit.

Tests on completion

The object of these tests is to demonstrate the fitness for purpose of the plant prior to take-over by the
Owner. The scope of tests shall include the following and any other tests the Engineer may reasonably
require to demonstrate the fitness for purpose of the plant:

a. demonstration of starting, shutdown and transient characteristics under both hot and cold conditions.
This shall include a successful demonstration of the one push button start up and shutdown of the plant

b. performance of the governing system and protective devices

c. grid compliance testing including MVAr capability, frequency response and AVR testing

d. unit load control tests.

The Contractor shall carry out the Tests on Completion. The plant shall be operated by the Owner under the
supervision of the Contractor. The Tests on Completion shall be satisfactorily passed prior to commencement
of the Performance Tests

Start up guarantee tests

The GT units shall be started both independently and simultaneously from their cold, warm or hot condition
and shall be shut down in a simultaneous sequence. The time elapsed from start initiation to base load for
each gas turbine and for the complete block shall be recorded and compared with the guaranteed maximum
start times provided by the Contractor.

Guarantee and performance tests

The Works will not be taken over by the Owner until satisfactory completion of all tests. The Performance
Tests shall be satisfactorily passed prior to commencement of the Reliability Test. The Noise Test and the
Environmental Tests may be undertaken in conjunction with the Performance Test. However, the emission
tests shall be performed at the same time as the Performance Tests. The Performance Tests and Reliability
Test shall be undertaken with operable and calibrated CEMS equipment. Failure of the CEMS will invalidate

Page 77 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
a Performance Test or Reliability Test. The scope of guarantee and performance tests shall include the
following:

a. performance guarantee tests (output, heat rate and environmental).

b. reliability test run.

Output and heat rate performance guarantee tests

5 General
Power output and heat rate of the overall power plant shall be determined in accordance with ASME PTC 22
or ISO 2314.

Whilst the performance tests shall be carried out on the plant as a whole and not individual plant items, this
shall not preclude the Contractor from the responsibility of undertaking the necessary demonstration
performance tests on major individual items of plant to either verify satisfactory operation or identify any
shortfall in individual plant performance.

Unless otherwise agreed each individual guarantee performance test shall be carried out for a period of 1
continuous hour, divided into three consecutive 20 minute evaluation periods.

The performance guarantee tests will consist of output and heat rate tests at full load on both fuel gas and
fuel oil. The performance guarantee tests will be performed after completion of commissioning tests but
before the reliability test as described in later in this section.

6 Conditions of test
During the contractual guarantee performance test the plant mode of operation shall be:

i. the plant shall be operated at full load

ii. all standby auxiliaries shall be operational

iii. variations exceeding steady state conditions shall invalidate the test run and shall be repeated

The facility shall be operated in a normal mode which is representative of a long term operating
configuration with all equipment operating as designed and within specification and alarm limits consistent
with good power generation industry practice. No normally operating systems should be taken out of service
including by passing or suppressing of alarms unless specifically allowed in the test procedure.

7 Correction curves
The tests results recorded during the Performance Test shall be corrected, as applicable, to those which
would have been achieved had the test been carried out at the guarantee basis conditions by using agreed
correction curves. Formulae describing the correction curves shall also be provided.

These correction curves and formulae shall be limited to:

i. correction for ambient temperature

ii. correction for humidity

iii. correction for barometric pressure

iv. correction for fuel calorific value and C/H ratio

v. correction for power factor

Page 78 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
vi. correction for grid frequency.

8 Metering
The net OCGT plant output for the performance guarantee tests shall be measured using the tariff meters.
The meters shall be capable of displaying kilowatt hours for the duration of the test.

All auxiliary loads that would normally be operating at the Guarantee Point shall be in operation during the
tests. A list of auxiliary loads shall be provided with the Tender documents and in the Test Procedure.

The fuel meters provided shall be of suitable accuracy for performance testing according to the appropriate
test code.

Procedures for measurement of other parameters such as ambient temperature, barometric pressure, relative
humidity etc shall be fully detailed in the Performance Test Procedure.

No test-measuring orifice plates, nozzles or Venturi tubes shall be installed without the approval of, and
witnessing by, the Owner.

9 Fuel analysis
The Contractor shall ensure that an analysis of the fuel before, during and after the test is performed and that
this data shall be submitted with other relevant test information in the final test report. The Contractor shall
supply the necessary apparatus for taking and containing the fuel samples. Three separate samples shall be
taken at each of the three sampling periods. One of each set of three samples shall be analysed by an
independent authority and the costs of these analyses shall be borne by the Contractor. One sample of each
set of three shall be properly labelled and handed over to the Owner. One set shall be maintained by the
Engineer in case of dispute of the results.

10 Instrument test measurement uncertainty


Just prior to the Performance Test every test instrument required for the measurement of test data shall be
checked and recalibrated if necessary

All instruments used in the Performance Test shall be of the standard, quality, and accuracy suitable for
performance testing as detailed in the Performance Test Procedure.

A pre-test uncertainty analysis shall be carried out to confirm that the selected instruments and test design
shall provide test uncertainties on corrected heat rate and power no greater than those given in the Test Code.
A post-test uncertainty analysis shall also be carried out to validate the test, the results of which shall be
included in the test report. The details and results of the pre-test and uncertainty analyses shall be included in
the test procedure.

Instruments for critical measurements shall be calibrated using standard reference sources or shall have been
previously calibrated and certified by independent nationally or internationally approved calibration
authorities.

Calibration certificates shall be provided for the test instruments at the time of test. The costs involved in
preparation of calibration certificates will be to the Contractor's account.

The corrected test result of net heat rate and net power output shall have no measurement uncertainty
correction applied. The Contractor's guaranteed performance figures shall be quoted accordingly.

11 Performance tolerances
The corrected test result of net heat rate and net power output shall have no tolerance correction applied. The
SIEMENS's guaranteed performance figures shall be quoted accordingly.

Page 79 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
12 Performance testing procedure
A Performance Test Procedure document shall be prepared by the Contractor for approval by the Owner and
shall be submitted to the Owner in its final form not less than six months prior to the programmed Test Date.

The Performance Test Procedure shall be a full and detailed procedure based on ASME PTC 22 or ISO 2314
and in accordance with the procedures, scope and details contained in this Specification. Curves and
correction factors to be used for the Performance Tests shall be based on the equipment vendor's standard
correction curves. The curves used shall be those included in the Contract.

The Performance Testing Procedure shall be in accordance with the pre-Contract Performance Test
Procedure and will be mutually agreed between the Contractor and the Owner or Owner's representative at
an early stage in the contract programme. The Performance Test Procedure shall include all calculations
showing the use of all correction curves and factors for each parameter. The Performance Tests shall be
witnessed by the Owner and the evaluated test results submitted to the Owner for approval. The format for
the Performance Testing Procedure will generally be as follows:

1. Scope of tests

2. Guiding principles

i. test dates and timetable

ii. preparation for tests

iii. method of tests

iv. plant mode of operation

3. Testing conditions

v. operating conditions

vi. constancy of test conditions

vii. maximum permissible variations in plant operating conditions

viii.duration of tests

4. Instruments and method of measurement

ix. define plant test parameters

x. list of test instruments

xi. calibration of test instruments (class of accuracy)

xii. instrument test measurement uncertainty

xiii. commercial panel instruments

5. Computation of test results

xiv. data acquisition system log sheets

xv. commercial panel instrument log sheets

xvi. frequency of readings

xvii. observers and labour

Page 80 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
xviii. specified requirements and guarantees

xix. fuel calculations

xx. correction curves and data

xxi. instrument list and diagram of test measuring points

xxii. diagram of electrical test measuring equipment

xxiii. instrumentation for electrical output

xxiv. current and voltage transformers.

Environmental performance guarantee tests


During the output and heat rate performance tests and the reliability test, the Contractor shall undertake
witnessed emission tests to demonstrate that the gas turbines meets all relevant environmental
requirements/planning consents. The duration of the emissions test shall be a minimum of 4 hours. Normal
plant start up and operating procedures should be used in operating the unit during the tests. All plant
systems will be in automatic control. The gas turbines shall be operated at base load, with tests to be
carried out on fuel gas and fuel oil.

Measurement of noise levels at the site boundaries shall be measured in accordance with the approach
defined in ISO 6190:1999 Acoustics - measurement of sound pressure levels of gas turbine installations for
evaluating environmental noise - survey method.

Prior to testing a measure shall be made of the background noise levels without the power plant operating.
Measurements shall preferably be made at night in a period of low background noise levels from other
sources and minimum off-site vehicle movement.

The measurement equipment shall comply with ANSI S1.4 precision standards. The test method shall be in
accordance with BS 4142:1007 or equivalent.

For work area noise acceptance tests, equivalent continuous levels shall be obtained at a minimum distance
of 1 m from the surface of equipment, acoustic enclosures, or room boundaries.

The results of the tests shall be fully reported together with operating conditions of the equipment,
meteorological conditions, noise measurements, instrument locations and instrument details.

Any increase in noise levels above that allowed in the Contract shall be investigated and should these be
shown to be because of noise emanating from new plant, then the Contractor shall remedy same at its own
cost by the installation of sound attenuation measures. Repeat tests shall then be carried out to demonstrate
that the remedial works have been successful in eliminating the noise problem.

Tests shall be undertaken on effluent and gaseous emission levels to ensure compliance with the stipulated
planning consents.

Reliability test
The reliability of the plant, complete with ancillary plant, equipment and services required for the full, safe
and efficient operation, shall be proved by starting fully automatically and by operating within the limits of
output specified, and either continuously or intermittently as may be more convenient for the working of the
station without interruption of any kind for a period of 7 consecutive days (168 hours), operating on fuel gas.

Page 81 of 82
MINISTRY OF ELECTRICITY General Directorate For DIBIS Tender
Gas Power Plant Projects 2011
The Contractor will be permitted to make any minor adjustments, which may be necessary, provided that
such adjustments do not in any way, interfere with or prevent the commercial use of the plant by the Owner,
or result in reducing the output, decreasing the efficiency or exceeding the environmental limits.

Should any interruption occur in any portion of the Plant, due to or arising from faulty design, material or
workmanship, a new reliability test period of 7 days shall commence after the Contractor has remedied the
defect.

a. An interruption is defined as:

b. Any plant failure resulting in a reduction in generation capacity from the requested power output.

c. Any deviation from the requested power output at of more than 2.5 per cent of requested output

d. Operation of equipment in manual mode which normally is operated in automatic mode

e. Switching over to the redundant auxiliary system because of failure

f. Failure of plant to start.

If for reasons beyond the control of the Contractor, the reliability test is interrupted, the test shall resume as if
the interruption had not occurred.

Test records
The Contractor shall be responsible for supplying to the Owner two copies of all test documentation for
precommissioning, commissioning, performance and reliability tests for the complete plant.

The Contractor shall promptly prepare and submit a detailed test report to the Owner/Engineer within 5
business days of completion of any test. The test report shall include the test procedure, description of any
deviations from the test procedure of unusual event(s), which occurred during the test, copies of test data
sheets, calculated results, copies of lab analyses, and copies of instrument calibration records.

Page 82 of 82