Appendix 7 - Tor Esco Hot Charging.pdf

July 2014

GFIRA12001 WBS: 120506-1-01-05-03 TERMS OF REFERENCE “Energy Efficiency in Key Industrial Sectors” This Terms of Reference will be used for the preparation of the bid for the supply of equipment and technical services for the implementation of hot charging of steel billets from Continuous Casting Machine No.5 (CCM No.5) to Rolling Mill 500 (RM 500) at Esfahan Steel Company (ESCo), Esfahan, Iran. This document specifies the scope of supply for equipment and services to be provided by the contractor in that connection. The proposal should contain a detailed description of the equipment and services to be provided and the key experts/personnel to be assigned for preparation the abovementioned proposal. The cost breakdown for each activity should be included in the proposal. All deviations from the Terms of Reference should be clearly indicated in the proposal.

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Table of Contents 1.

General Information and Bidding Requirements............................................................................. 2

2.

Definitions ....................................................................................................................................... 2

3.

Description of Required Services ................................................................................................... 6

4.

Functional Description .................................................................................................................... 8

5.

Provisional List of Equipment/Supplies ......................................................................................... 18

6.

Training Requirements.................................................................................................................. 20

7.

Provisional Work Schedule ........................................................................................................... 22

8.

Contractor's General Responsibilities ........................................................................................... 24

9.

Counterpart’s Responsibilities (ESCo) ......................................................................................... 24

10. Terms of Guarantee ...................................................................................................................... 25 11. Reporting Requirements ............................................................................................................... 26 12. Evaluation Criteria ......................................................................................................................... 26 13. Performance Tests, Guarantees and Penalties ............................................................................ 28 14. Spare Parts ................................................................................................................................... 32 15. Quality Assurance & Quality Control Plan ...................................................................................... 33 16. Specification for packing, Marking and forwarding ......................................................................... 42 17. Instruction of Submission of Drawing and Document ..................................................................... 59 18. PERFORMANCE GUARANTEES AND TEST POCEDURES ..................................................... 83 19. Technical Appendices ................................................................................................................... 87 Appendix A – Company Information ................................................................................................. 87 Appendix B – ESCO construction steel product brochures for beam, equal angles and channels .. 95 Appendix C – CCM No.5 technical and product specification .......................................................... 96 Appendix D – CCM No.5 Product quality guarantees ..................................................................... 100 Appendix E – CCM No.5 technical drawings .................................................................................. 101 Appendix F – Technical description of RM500 billet heating furnace ............................................. 105 Appendix G – RM500 furnace original side drawing ....................................................................... 108 Appendix H – RM500 furnace control and automation and system................................................ 109 Appendix I – Possible hot charging layout and modified CCM No.5 .............................................. 110 Appendix J – What is hot charging? ............................................................................................... 111 Appendix K – Preliminary list of equipment, supplies and services ................................................ 112 Appendix L – Site Photographs ...................................................................................................... 114 Appendix M – Definition of the scope of supply .................................. Error! Bookmark not defined. Appendix N – Definition of Contractor Vendor list .............................. Error! Bookmark not defined.

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1. General Information and Bidding Requirements 1.1 Background This Project is a contract under the GEF-funded project titled Industrial Energy Efficiency in Key Sectors” led the United Nations Industrial Development Organization (UNIDO). The objective of the project includes the implementation of a demonstration energy efficiency project (i.e. “The Project”) in the Iranian iron and steel sector and promotion of sector-wide uptake of the selected energy saving technology. The executing partner is the Iranian Fuel Conservation Company (IFCO) and focal sectors include iron and steel production. The beneficiary steel company is Esfahan Steel Company (ESCo). 1.2 This Document The objective of this document is to form the basis of the procurement process for the implementation of the Demonstration Energy Efficiency Project and to appoint the lead Contractor under an Engineering, Procurement and Supervision (EPS) contract arrangement to implement the Project. The Terms of Reference (TOR) defines all technological aspects and functional requirements of the hot charging Project to be engineered and supplied to the Counterpart (ESCo) by the appointed Contractor. The technical aspects include the following sections: •

Definitions

• •

Description of Technical Services Functional Description

• •

Provisional List of Equipment/Supplies Provisional Work Schedule

•

Training Requirements

•

Technical Appendices

The TOR also defines the responsibilities and scope of services to be provided by the Contractor and Counterpart.

2. Definitions 2.1 Project The Project will implement a “hot charging” solution to transport hot billets from Continuous Casting Machine No.5 (CCM No.5) to existing Rolling Mill 500 (RM500) reheating furnace. The Project will charge the reheating furnace with hot billets directly from CCM No.5 at temperatures approximately 700°C. During stoppages the furnace shall be charged with cold billets from the stock yard( existing Equipment). Overall, the furnace shall be charged at a ratio of approximately 70% hot; 30% cold individually. The Project should achieve significant production and energy cost savings. 2.2 Counterpart The Counterpart is Esfahan Steel Company (ESCo). The Project will be implemented at the Counterpart’s primary industrial premises – an integrated steelworks located outside Esfahan, Iran. 2.3

Implementing Agency

The United Nations Industrial Development Organization (UNIDO) is the Implementing agency. UNIDO will support the Project and is responsible for managing the tender and procurement process and executing payments to the Contractor.

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2.4 Contractor The Contractor will be contracted for all engineering, procurement & manufacturing ( main contractor scope of work ) , training , and Supervision for erection and commissioning (EPS) tasks as specified under a single EPS contract arrangement. 2.5 Hot charging Hot charging normally involves charging temperatures of between 300 to 800°C directly from the continuous casting machine to the reheat furnace. Hot charging is normal practice in the steel industry and has several benefits including significant energy cost savings when compared to cold charging. (The best available billet transfer technique is direct rolling of billets of around 900 to 1000°C directly to the rolling mill.) 2.6 Rolling Mill 500 (RM500) Rolling Mill 500 (RM500) is a medium section hot rolling mill with production capacity of 1 million tonnes/year (965,685 tonnes were rolled in 2012). 2.7 RM500 Reheating Furnace RM500 uses a walking hearth reheating furnace to reheat billets from ambient temperature up to 1250°C before rolling. 2.8 Continuous Casting Machine No.5 (CCM No.5) ESCo is constructing a new 6 strand billet continuous casting supplied by DANIELI. CCM No.5 is currently under construction and commissioning expected in the First half of 2015. CCM No.5 will produce 1million tonnes/year of low, medium and high carbon steels and high strength low alloy steels (about 90% low and medium carbon steels in total). Plant includes continuous caster, mould, oscillator, oxy cutting station for billet cutter, billet cooling, conditioning, storage and dispatch section along with all associated services, utilities and systems. 2.9 Steel billets CCM No.5 will produce Semi-finished continuous cast steel billets used for the rolling of long products (of square shape with cross sections of 150 x 150 mm to 200 x 200 mm). 2.10 Rolled steel products RM500 produces low, medium and high carbon, and high strength low alloy constructional steel products, including flanged I-beam, equal angles, flanged channels. 2.11 Steel grades RM500 produces grades: St 37-2, St 44-2 and St 52-3 (Equivalent standard EN 10025: S235JR, S275JR and S335JR). 2.12 Site Conditions 2.12.1 Location This plant will be located in the way of Esfahan-Sharekord (45 km from Esfahan city), Esfahan province in the centre. Esfahan City is located in Esfahan province, approximately 800 Km far from Bandarabbas port in south of Islamic Republic of Iran.

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2.12.2 Site elevation 1757.5 meter above sea level 2.12.3 Accesses A) Railway and freeway connection to plant B) Roads

The traffic width for bridges and culverts is road worthy. Maximum width of traffic for carry equipment is 3.5 m and maximum height is 4.5 m. Maximum trucks axle force for lone axle is 13 tons and couple axle is 20 tons. Maximum allowable weight of truck and loads in roads is 40 tons. C) Ports

Normally equipment will be shipped to southern Iranain ports (Persian Gulf). The main ports are Imam Khomeini port, Bandar Abbas port, Booshehr port. Alternatively Anzali port on Caspian Sea may be utilized, for equipment shipment. D) Air port

The nearest of international airport to site is Shahid Beheshti airport (25 Km from Isfahan city 70 Km from the site).

2.12.4 Atmospheric temperature Max.

+41.8 °C

Min.

-17.8 °C

Average temperature in summer Average temperature in winter

+28 °C -5 °C

2.12.5 Soil temperature Freezing zone depth of soil:

<500 mm

2.12.6 Atmospheric pressure Max.

626.9 mm Hg

Min.

603.2 mm Hg

2.12.7 Wind Max. Speed

48 m/sec.

Wind directions-predominant

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21.6% Northwest 15.2% Southwest 13.8% Southeast 13.2% west

2.12.8 Evaporation Daily evaporation from free surface:

18.48-25.10 mm daily 2,614.98-3,559.82 mm annual

2.12.9 Relative humidity Average Relative humidity

30%-50%

Maximum Relative humidity

100%

Minimum Relative humidity

1%

2.12.10 Precipitation Rainfall + Snowfall max. yearly precipitation

293.2 mm (1986)

max. monthly precipitation

90 mm

max. daily precipitation

62.1 mm

min. yearly precipitation

79.3 mm (1973)

2.12.11 Ground water Ground high:

close to surface

Quality:

saline and corrosive (i.e. sodium sulphate, sodium chloride)

2.12.12 Seismic factor: Esfahan is located in a zone of medium relative seismological danger. The codes used in seismic calculations have to follow the standard IRAN-2800.

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2-13. Utilities Data

1

Compressed air

4.5 atm ( gauge )

2

Water

4.0 atm ( gauge )

3

Frequency

50 Hz + 1%

4

Main supply

10 kv , 3 phase

5

Plant distribution

380 v , 3 phase

6

Up to 75 kw

380 v, Direct on line starting

75kw

380 v, Delta / star

Electrical

to 160 kw

starting

160 kw to 315 kw

380 v, soft starter starting

Over 315 kw

10 kv , delta / star starting

3. Description of Required Services UNIDO seeks an experienced international engineer and supplier of steel billet handling equipment to engineer, procure and manufacturing and supervision the Hot Charging Project. The scope of technical and supply services to be provided should consist of, but not be limited to, the following items. 3.1 Project implementation The Contractor will be fully responsible for the implementation of the project as specified in the Project Functional Description (see Section0). 3.2 Engineering, procurement & manufacturing and Supervision (EPS) The Contractor will be contracted for all engineering, procurement and Supervision (EPS) tasks as specified under a single EPS contract arrangement. 3.3 Subcontracting The Contractor is encouraged to deliver the project in partnership with one of more local engineering companies under subcontracts (e.g. to procure mechanical equipment, undertake civil and construction works etc) in order to be cost effective. Subcontractor should be approved by UNIDO/ESCO 3.4 Site survey The Contractor's team leader should visit the project site prior to submit their offer (technical and commercial proposal) execution in order to: •

Become familiar with the Counterpart's (ESCo) premises, local conditions and the Counterpart's requirements and expectations

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•

Clarify and advise on technical and other responsibilities of the counterpart

•

Adjust the technical specification of supplies to the local conditions and

•

Discuss and harmonise with the Counterpart and UNIDO the proposed work plan and schedule of the overall conversion process

Photographs of the site are provided in

Appendix K. 3.5 Engineering design The Contractor will design all engineering aspects of the Hot Charging Project. The Contractor will prepare and deliver detailed engineering drawings, technical documentation, manuals and list of spare parts of all new and modified equipment manufactured by the Contractor and local contractor (Esco. Scope of work)(i.e. the “Engineering Design”). A suggested concept design, prepared by ESCO’s engineering department, is presented in Section 0. 3.6 Equipment procurement The Contractor will procure all equipment as required and specified by the Engineering Design including equipment, bulk materials, first fills, operating consumables and spares. The suggested provisional list of equipment is presented in Section 0. 3.7 Transportation and related costs The Contractor will be required to transport any International equipment to Iran and to site ahead of erection. UNIDO will assist this process by procuring and importing any International equipment supplied by the Contractor into Iran and ensuring compliance with the United Nations Security Council Sanctions list of prohibited equipment to ensure no equipment is in violation of such items. 3.8 Construction The Contractor is also invited to offer any management and supervision services to ensure successful implementation of the Project. This supervision will include, but not is not limited to the following. •

Site establishment, pilling, foundations, civil works execution

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•

Plant erection

•

Equipment installation

•

Commissioning and start-up, performance test and handover

3.9 Management and supervision services The Contractor is also invited to offer any management and supervision services to ensure successful implementation of the Project. This supervision will include, but not limited , the following. •

Site establishment, pilling, foundations, civil works execution

• •

Plant erection Equipment installation

•

Commissioning and start-up, performance test and handover

3.10 Training services The Contractor will provide training services (including abroad /insite training) and all required documentation as specified in Section0. 3.11 Production assistance The Contractor is also expected to provide production assistance to the Counterpart following commissioning and start-up, performance testing and handover of the Project equipment (i.e. postcommissioning), to ensure a smooth transition of production is achieved. 3.11.1 Post-commissioning monitoring and troubleshooting site visit The Contractor is expected to conduct post-commissioning monitoring and troubleshooting visits to the Counterpart’s site four (4) months after handover, as required by the Counterpart. 3.11.2 Preparation of Safety Document Prepare and submit a Safety Document including all technical, training and legal requirements dealing with industrial safety in line with the best available international industrial practices and local regulations. The aim of the Safety Document is to prevent major accidents which might result from any hazardous industrial activities at the steel plant and to limit the consequences of any mishaps for man and the environment. The documentation has to be prepared in time (not later than one (1) months prior to shipment of equipment) to enable ESCo to take the necessary measures required from their side. Involvement of Counterpart's staff in the process of preparation of the Safety Document is required.

4. Functional Description The Project’s required function, scope and technical performance is defined as follows. 4.1 Project Function and Scope The hot charging project will transport hot steel billets directly from the new CCM No.5 to the RM500 heating furnace, thus connecting the continuous casting and rolling processes into one continuous process. The existing production process flow and steps involved in converting pig iron into rolled steel are shown in

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Figure 1.

Figure 1: Overview of the existing production process at ESCo from steelmaking to rolling.

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Pig Iron& DRI

Basic Oxygen steelmaking (Converter) 1610°C

Ladle Furnace

Sampling

1580°C

Billet Continuous Casting

Quality Control (QC)

Cold Charging

925°C

Billet Cooling Bed

Rolling Mill 500 Heating Furnace

Billet cooling and storage 350°C

25°C

Rolling Mill 500 1250°C

Rolled Steel

The proposed new process including hot charging between CCM No.5 and reheating furnace is shown in Figure 2 overleaf. 4.1.1

Aim of hot charging

The aim of hot charging is to minimise conveying time and maximise the charging temperature of billets (within the technical limitations) in order to reduce the fuel consumed by the furnace to reheat the billets to the discharge temperature of 1250°C (and so maximise the potential energy and cost savings). The system should allow for the required level of quality control and must not jeopardise product quality downstream.

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Figure 2: Proposed new process including hot charging between CCM No.5 and heating furnace. Hot metal/Pig Iron

Basic Oxygen steelmaking (Converter) Sampling

1610°C

Ladle Furnace Billet Cooling & Cold Charging

30% at 25°C

1580°C

Billet Continuous Casting

Rolling Mill 500 Heating Furnace

Quality Control (QC)

1250°C

925°C

Hot Charging

4.1.2

Rolling Mill 500

70% at 700°C

Rolled Steel

Expected benefits

The expected benefits, compared to the current practice of 100% cold charging, include the following. •

Significant energy and production cost savings.

• • •

Increased production and throughput, and reduced overall production times. Reduced waste, higher yields and improved product quality due to reduced scaling, oxidation and decarburisation. Reduced use of crane for billet transfer (reduced operation and maintenance costs).

•

Reduced billet surface and dimension defects caused by crane transfer.

4.1.3

Suggested hot charging concept design

A scale drawing of the CCM No.5 and a possible hot charging solution is shown in Figure 3. To facilitate hot charging, a simple modification and additional handling equipment has been proposed by ESCo’s engineering department. The original design shows that after primary cooling, billets are cut at a temperature of 975°C and transferred along a roller table to cross transport. The cross transport table then transfers billets at 925°C to the cooling bed on the right hand side where the billets then cool to 430°C before transfer to the collection table and on to the stock yard for cooling and inspection. Hot charging could be achieved by modifying the cross transport to enable distribution of billets in both directions (or by retrofitting a pushing device). Hot charge billets could then be transferred to the left hand side into alignment with the roller table axis, lifted to correct elevation and then charged to the directly to furnace over the minimum distance. There is space available to construct lifting equipment to the left of CCM No.5 cross transport. A roller table (capable of sending one billet at a time) could also be constructed to transport hot billets to the furnace roller table. Automated inspection equipment could be included between the CCM No.5 cross transport table and the furnace roller table. Also 2 hot billet storage area with capability of 35 hot billet ( totally – 1 CCM heat ) storage should be considered because of some interference between CCM production and rolling mill

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condition. The fixed stopper located at the start of the furnace roller table may have to be replaced by a retractable stopper with control system. Based on the CCM capacity (Max. 1.2 MTPY), this project should be able to transfer all billets produced by CCM and minimum capacity of billet transferring should be consider 30 second per each billet. Figure 3: Schematic Top view of the new continuous caster and a drawing of a possible layout of billet transport equipment to charge hot billets from the CCM No.5 to the RM500 furnace

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4.2 Steel product and grades Rolling Mill 500 primarily produces constructional I-beams. About 90% of production is I-beams of sizes 14 and 18(i.e. with heights of 140 and to 180mm) and made from low and medium carbon steel. The steel grades include St 37-2, St 44-2 and St 52-3 (Equivalent standard EN 10025: S235JR, S275JR and S335JR). 4.3 Billet charging temperature The hot charging system will transport hot steel billets directly from the CCM No.5 to the RM500 heating furnace at a temperature of approximately 700°C. The actual hot charging temperature achieved could be higher and should be maximised in order to increase energy and production cost savings (also by using special covers on transfer area) . 4.4 Percentage of hot charging and cold charging The reheat furnace may also be charged with cold billets from the stock yard. It should be possible to charge the furnace directly with hot billets for at least 70% of overall production. Cold billets can be charged during stoppages or to allow for rolling of special steels which require billets from other sources. A minimum hot charging percentage of 70% hot; 30% cold over the total production period is expected. The actual hot charging percentage achieved could be higher and should be maximised in order to increase energy and production cost savings. 4.5 Billet quality and automatic inspection equipment Hot charging is normally applied only if billet surface quality is good enough so that cooling and scarfing is not required and billets can be charged directly to the furnace (without need for inspection). CCM No.5 includes mould electromagnetic stirrers (M-EMS) which significantly improves billet quality and productivity. Additionally, the surface and dimensional quality of billets produced by CCM No.5 are guaranteed by the supplier, DANIELI. Copies of the product quality guarantees are provided in Error! Reference source not found.. In compliance with their billet surface quality control standards however, ESCo requires inspection of hot billets to be included to ensure product quality downstream. Therefore, the project should include automated, high-temperature inspection equipment and a billet rejection handling system to verify compliance with quality control requirements. ESCo has suggested the solution could include ultrasonic and/or magnetic flux leakage flaw detection technologies capable of testing hot surfaces. 4.6 Status, implications, layout and configuration of CCM No.5 ESCo is constructing CCM No.5 – a new 1 million tonne/year continuous caster capable of producing billets with cross sections of between 150 x 150mm and 200 x 200 mm at lengths of between 6 to 12m. The equipment has been supplied by DANIELI. The technical specification of CCM No.5 is summarised in Table4 in Appendix C. The product specifications are shown in Table5 in Appendix C including billet dimensions, casting speed and throughput. Side view and top view drawings are displayed in the Appendix D – CCM No.5 Product quality guarantees (see overleaf)

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Appendix D. 4.6.1

Implementation Status

CCM No.5 is currently under construction and commissioning expected in the first half of 2015. The CCM No.5 equipments have already been manufactured and now are under installation in site. 4.6.2

Implications for hot charging

The layout and configuration of CCM No.5 and surrounding non-critical buildings/structures should not restrict the implementation of hot charging. However, the hot charging project may require modifications to the CCM No.5 (e.g. cross transport table function and foundations). Further, the hot charging project should proceed as soon as possible to minimise any potential delay to the CCM No.5 project. It is noted that the cross transport table is unidirectional (i.e. billets can only be transported in one direction towards the billet cooling bed). Therefore, additional equipment may have to be retrofitted to the CCM No.5 in order to facilitate the hot charging function. 4.6.3

Plant layout and available space

The layout of CCM No.5 is shown in Figure 6 in Appendix D – CCM No.5 Product quality guarantees (see overleaf)

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Appendix D. This indicates that available space for additional equipment between caster and furnace is limited. In terms of obstacles, there is a line of structural steel supports supporting the roof of the workshop. The existing layout is not considered to restrict the implementation of hot charging. However, the contractor should conduct their own site survey to gather sufficient information prior to Engineering Design. 4.7 Transport distance The horizontal distance between CCM No.5 billet stopper and the furnace roller table is 20.3m, vertical distance is 1.5m and lateral distance from the CCM cross table axis to the furnace roller table axis is approximately 3m. The exact distances should be verified by the Contractor during a site survey. 4.8 Casting speed and throughput The target production capacity of CCM No.5 and RM500 is around 1 million tonnes per year. The casting speed and throughput of CCM No5 are listed in Table5 in Appendix C. Casting speed ranges from 1.5 to 3.5 metres per minute and overall throughput from 164 to 215 tonnes per hour. ESCo estimate that typical average throughput will be around 1.4 metres per minute. The exact casting speeds should be confirmed with ESC according to the planned billet and steel specifications to be produced by CCM No.5. 4.9 Rolling mill 500 heating furnace The RM500 heating furnace is described in

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Appendix E, Appendix F and Appendix G in detail. During operation, the temperature of the RM500 walking hearth heating furnace should be kept as close to constant and any change in temperature must happen gradually in order to prevent damage to the refractory, in compliance with the furnace’s operational guidelines. The temperature of each of the six firing zones must be in accordance with the type of steel, charging temperature and required rolling temperature. Normally, hot charging results in a reduction of hot billet residence time (e.g. 120 to 80 minutes) resulting in energy savings and increased productivity. However, consecutively charging hot billet followed by cold billets (or cold followed by hot) introduces changes in charging temperature and risks damage to the refractory. Therefore, changes in charging temperature during operation should be minimised and changes must be controlled carefully to maintain the specified temperatures. Technically, it is considered possible to charge the furnace with cold and hot billets consecutively without modification or additional automation to the heating furnace. Energy savings can be achieved by reducing fuel consumption when charging at higher temperatures and in order to maintain the correct temperatures in each firing zone and the overall energy balance. However, ESCo is concerned that maintaining the correct temperature by manually reducing or increasing fuel supply may be difficult given the current status of furnace control and automation and will subsequently increase the risk of damage to the furnace. To reduce this risk, the proposed Hot Charging Project must include recommendations for furnace operation and control for handling the switch between hot billets and cold stock (e.g. recommended furnace zone temperatures profile for different cold and hot charging temperatures, fuel supply, energy mass balance etc). Additionally, switching between cold and hot charging must also be continuous with no significant delay (e.g. delays to allow for specified gradual temperature changes) in the heating zones that could then adversely affect the hot rolling schedule. To overcome this challenge, the hot charging project could include the addition a hot buffer for preheating cold billets, for example, or other appropriate solutions, as deemed necessary by the Contractor and specified in the Engineering Design. Significant modification to the RM500 rolling line (for the purposes of increasing production throughput) and the significant upgrade of RM500 furnace (to increase the control automation level) is considered outside the scope of the Hot Charging Project. Moreover, the other modifications required for adopting the RM 500 furnace to CCM 5 relate to Hot Billet charging project. 4.10 Production planning and process control Introducing hot charging and thus linking the casting and rolling processes into a single, continuous process suddenly speeds everything up, increases the temperature at which billets are handled and transferred to the rolling mill and reduces time for quality inspection. Overall control of the casting and rolling processes must to be aligned to balance CCM No.5 output and RM500 furnace input. In order to achieve this alignment, the Hot Charging Project must include an adequate managerial and control solution. It is expected that this will include a degree of automated control for hot billet handling and furnace charging.

5. Provisional List of Equipment/Supplies The hot charging system will consist of mechanical, hydraulic, control, automation and electrical equipment (including motors and drives). The final equipment will depend on the Engineering Design provided by the Contractor. A preliminary list of main equipment has been proposed by ESCo’s

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engineering department, shown in Table 1. It is expected that certain equipment can be procured locally but more advanced plant will have to be imported. The full breakdown of proposed equipment is included in Appendix J. Table 1 Preliminary list of main equipment for the hot charging system.

No.

1 1.1

Equipment

Suggested source of supply

Mechanical and hydraulic equipment Modifications of CCM No. 5 cross transfer system and comb transfer system

_

Steel structure of Collecting and Billet cross transport table

1 set (Billet cross transport table)

1.2

1.3

Quantity

Steel structure of Lifting/rotating equipment

Local

Local

Steel structure of Pulling mechanisms

1.4

Local

2 sets of lifting gears

Local

1.5

Steel structure of Pushing machine

Local

1.6

Steel structure of Intermediate storage table 1

Local

1.7

1.8

1.9

1 set Billet cross transport

Local

Steel structure of Billet cross transport equipment 1

Steel structure of Roller Tables

24 Sets of Roller

Local

Quality control system

1 set

Steel structure of Billet cross transport equipment 2

1 set Billet cross transport

1.10

International Local

1.11

Steel structure of Intermediate storage equipment 2

Local

1.12

Steel structure of Reject table

Local

1.13

Steel structure of Billet cross transport equipment 3

Local

1.14

Hydraulic unit and equipment (all hyd. cylinder and accessories included )

International

1.15

Hydraulic components and accessories on board

International

19

1.16

Oil and grease lubrication system and accessories included

International

1.17

Compress air system and accessories included (in battery limits)

International

1.18

All gear boxes , gear motors , bearings ,seals, ropes, chains, wheels , … and all other catalogue items of all mechanical equipment base on Appendix N – Definition of Contractor Vendor list

International

2

Process electrical system 24 gear motor sets

International

2.1

All Electric motors & drives and components

2.2

Electrical panels and desk

2.3

Earthing system

Local

2.4

Interconnecting cabling (cable list, terminal list, …)

Local

2.5

Steel cabins for switchboards and pulpits

Local

International

3

Process automation and control systems

3.1

Process control automation and components

1 set

International

3.2

Quality inspection automation and control equipment

1 set

International

3.3

Field instruments devices and accessories and components

3.4

Interconnecting cabling (cable list, terminal list, …)

3.5

Material Tracking

International Local International

6. Training Requirements The required training to be provided by the Contractor to the Counterpart’s personnel is described as follows. 6.1

Training should be led by experts from the Contractor (and subcontractor(s) as requires) across all aspects of the Project, including, but not limited to, billet quality inspection, billet handling system and automated control systems.

6.2

Management and operational staff from the ESCo’s Steelmaking, Quality Control, Rolling Mill 500, Automation & Control, Energy Management and Engineering teams should undertake the training.

6.3

The Contractor should provide sufficient training in the control, operation and maintenance of the hot charging system to ESCo’s technicians, operators and maintenance personnel, to ensure smooth transition of production from before and after the hot charging intervention. 20

Training should involve abroad / onsite training at similar company (equipped with hot charge system) / ESCo’s steelworks following commissioning and performance testing(estimated two months onsite training course). 6.4

Similar workshops to be held in the operation of the hot charging (with similar productions) equipment and control system (estimated two man months).

6.5

Additionally, a broader training programme is recommended for the Steelmaking, Quality Control and Rolling Mill 500 teams in advanced production management and scheduling techniques to prepare the team for the introduction the hot charging system and ensure the management systems are properly aligned.

6.6

External training in all engineering aspect related to hot charging at the premises of the design/lead supplier of the technology has been requested by the ESCo’s engineering department (estimated two man months).

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7. Provisional Work Schedule 7.1 7.2

The provisional work schedule is presented below. The exact dates for contracting and target dates/deadlines for project task completion are to be confirmed by UNIDO and the Counterpart. A work schedule similar to that outlined above is envisaged to be submitted by the Contractor for the engineering, fabrication, purchase/subcontract, deliver, supervision on installation, and commissioning of the plant and training of plant personnel.

7.3

To ensure a harmonious and coherent construction process and to coordinate all work and activities to be performed by the Contractor and the Counterpart, the main activities and responsibilities of both parties are specified in Section 0 and 9.

7.4

Major deviations from this proposed schedule should be indicated and discussed in the Contractor's tender.

7.5

The delivery time of documentation should allow sufficient time for the Counterpart to carry out the necessary work required from it.

7.6

The equipment should be delivered to the plant site according to Project Time schedule and neither the timing of the delivery of services and equipment nor their scope can be modified without the written consent of UNIDO. Please note that speed of delivery is of utmost importance. The project is intended to be completed by March 2016. The contractor should deliver as part of the proposal an appropriate time schedule taking into account the activities listed below:

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8. Contractor's General Responsibilities The appointed Contractor will undertake timely implementation of the following obligations. 8.1

The Contractor is responsible for applying the internationally best available industrial practice in hot charging of steel billets.

8.2

The Contractor is responsible for ensuring that all equipment supplied through the contract are new equipment of recent conception, free of defects and operational failures.

8.3

The Contractor is responsible for the control of all the work, services and supplies which are executed by its subcontractor(s) and will supervise the work, services and supplies provided by the Counterpart or its subcontractor(s) with regard to the implementation of the conversion process. If the above work/services/supplies are not satisfactory and/or do not correspond to the agreed requirements, terms, schedules and/or safety standards, or if the training of the staff does not reach the standards necessary for a safe operation of the converted production lines, the Contractor is obliged to intervene and to request fulfilment of such provisions, work, services and supplies and to timely inform UNIDO as well as the Counterpart accordingly.

8.4

The Contractor's responsibilities are valid up to the expiration of the guarantee period. The Contractor is required to intervene and to rectify each operating defect or irregularity which is due to a fault of the original design, manufacturing or material.

8.5

Make all required mechanical, piping, electrical, instrumentation, testing and any other work, labour, services, supplies, utilities and supporting systems, for the erection, commissioning and start-up of equipment and for the trials, test runs and full scale safe production (if required, this work will be defined and specified in cooperation with the Counterpart).

9. Counterpart’s Responsibilities (ESCo) The Counterpart (ESCo) will undertake timely implementation of the following obligations. 9.1

9.2

Provision of all utilities, of required quality and quantity at the points of connection to the equipment, and supporting systems, as required by the Contractor (if required, this work will be defined and specified with the assistance of the Contractor immediately after the contract has been awarded). This may include the following. •

power connection including the power switches

•

earth system

•

water supply

• •

compressed air supply ( out of battery limit ) Site establishment, pilling, foundations, civil works execution

• •

Local manufacturing ( base on scope of work T.O.R / S.O.S) Civil work

•

Plant erection

• •

Equipment installation Commissioning and start-up, performance test and handover

•

High pressure fire extinguishing water etc.

Relocation of any production or civil equipment if it is found necessary by all parties.

24

9.3

Provision of all required documents and permits from respective authorities related to the site, construction, and re-construction or equipment installation.

9.4

Written statement(s) that the utilities will meet the contractor's requirements within a specified time as agreed with UNIDO and the Contractor.

9.5

Adequate care, in-plant transportation, lifting and storage procedures of equipment at the project site prior to and during the period of erection until final acceptance will be trained in start up the project by HSE department.

9.6

Fully operational testing utilities before start of commissioning of the equipment.

9.7

All data, information, drawings, documents etc. required by the Contractor and/or UNIDO related to existing equipment of this site for the successful implementation of the Project.

9.8

Organizational and logistic assistance as well as support for the Contractor and UNIDO during and in connection with their activities on site.

9.9

Provide transportation of equipment from the harbour or airport to which it is delivered in Iran to the project site are not under of ESCO responsibility. Then adequate care, storage and insurance of equipment during the above transportation within the country and subsequently at the project site during the period of erection will be excluded.

9.10 The title and ownership rights of the equipment purchased through the project will be transferred to ESCo upon completion of the projects in accordance with the provisions of the project documents. Until that time, the ownership rights of the equipment remains to UNIDO. 9.11

All civil engineering and construction work required for the overall implementation of the Project (if required, this work will be defined and specified with the assistance of the Contractor immediately after the contract has been awarded).

10. Terms of Guarantee 10.1 The Contractor should guarantee the quality and completeness of all its work, supplies and services specified in Section 3 above. 10.2 The terms of mechanical, electrical, performance and safety guarantee for the equipment supplied, and processes/technologies transferred should be quoted in accordance with the international practice and standards. The duration of the guarantee should be at least twelve (12) months from the date of final acceptance of the plant in line with the terms of the contract. 10.3 The Contractor guarantees that the proposed scope of supply and services is complete and will allow the achievement and continued production of steel billets from CCM No.5 and rolled steel products from RM500 and in the agreed quantities and quality and in accordance with specified standards. 10.4 The contractor guarantees that the furnace is charged continuously with hot billets at a nominal temperature of 700°C for 70% of production time and charged from cold stock at 30%.

25

11. Reporting Requirements The Contractor shall submit the regular reports in English language as important obligations as follow in order to monitor and control the project status and progress according to the timetable and all deliverables included in the contract. 11.1. Progress report 1, to be submitted within 1 month of the contract signature and latest after the first visit to the project site and will include project work plan, project timetable, project Gantt chart (including milestones, critical path etc.) 11.2. Progress report 2, to be submitted following delivery of the equipment to the project site (month 9) 11.3. Progress report 3: covering the installation and commissioning of the equipment (month 12) 11.4. Progress report 4: covering the training on operation and maintenance (month 15) 11.5. Draft Final report, upon completion of the total work describing all the works performed under the contract (month 18)

12. Evaluation Criteria 12-1 The necessary conditions that determine the tender offer’s confirmation at first are: I.

At least one similar (hot charge) project in last 5 years must be implemented. The relevant performance’s contractor must be desirable and the document of previous owner’s consent is needed. However, the confirmation would be done by surveying the submitted documents, as an example: contracts, consent’s letters, and maybe visit of the implemented projects and also search and inquiry method.

II.

The confirmed supplier’s countries are: West Europe, North America, Japan and South Korea.

III.

Submission of operation and maintenance training.

IV.

Obtaining of at least 65 score from the table of followed technical-commercial evaluation:

Table of technical-commercial evaluation for tender offers #

Technical commercial indices

Obtained Score

1

Accordance of offer context completeness according to the enclosed table No. 1 in following

40

2

Offered Time schedule for design and engineering , supplying of equipment , project execution supervision till final project delivery (will be compared according to Time schedule)

6

3

Submit supplier and manufacturer of equipment (type and origin of equipment) ,comparatively

15

4

Quality and quantity of erection and commissioning supervision in during the commissioning and 4 month after commissioning with offered chart of supervision and technically man month segregated (will be compared)

5

26

5

The duration of guarantee of all parts and equipment and performance of whole system after commissioning (for every 3 months excess one year 2 scores)

4

6

Submit training plan in detail for erection and commissioning, operation and maintenance, comparatively

2

7

Submit list of Commissioning and operation spare part during of guarantee period

4

8

Submission of tender offer in the completely, vivid, and separated manner on the basis of titles and rows of technical-commercial evaluation criteria table with related table of contents to facilitate the evaluation of tender offer, comparatively

3

9

Reference list of similar projects, comparatively (for each similar project in 5 latest years 5 scores)

15

10

Quality control procedure and construction standards, comparatively

6

Total

100

12-2 The price affected by technical score in order to determining the winner is calculated by the following formula: Balanced price=Proposed price/ (40+60 %( technical score)) * 100 Table No.1:

#

Subject

Max. Obtainable Score

1

Submission a full list of equipment on the basis of tender documents

3

2

Submission of Equipment arrangement & general layout

3

3

Submission of UFD,P & ID,PFD

5

4

Submission of proposed design for modification of current venture

9

5

More usage of current equipment, comparatively

5

6

Submission of system’s specifications completely including energy consumptions, method of maintenance and repair, repair’s graph, etc.

4

7

Submission of manufacturer and supplier of equipment and main parts and subsidiary parts( both for Iranian and International supplier’s list will be compared)

8

8

Submission of initial spare part’s list(for 2 years production after final project delivery)

1

9

Submission of material and part’s list for pre-

1

27

commissioning ,commissioning and 18 months operation period 10

Submission of full technical information and main equipment catalogues and relevant system’s documents

1

13. Performance Tests, Guarantees and Penalties 13.1. Preliminary Acceptance Test (Cold Test) Preliminary Acceptance (PAC)

-

On completion of erection of the PLANT including utilities and auxiliaries, preliminary acceptance tests (cold tests) shall be performed for starting-up and commissioning.

-

Cold tests shall be performed on the individual equipment/ sub-assemblies of the PLANT and shall be designed to conduct the systematic check of the components and of the functional operation thereof.

-

Cold tests comprising idle, no-load and under-load tests shall be conducted under sole responsibility of supervisory personnel deployed by the SUPPLIER and in the presence of supervisory personnel of EMPLOYER. The EMPLOYER shall, for the purpose of cold tests, provide skilled operating personnel.

-

Detailed programmer of cold tests shall be drawn up by the SUPPLIER two (2) months in advance of cold test and shall be submitted to EMPLOYER for approval. Such programmer may be revised and adjusted during the test run as may be mutually agreed.

-

Results of cold tests shall be recorded jointly be the SUPPLIER and the EMPLOYER.

-

On successful completion of preliminary acceptance tests, and liquidation of the defect lists (except minor defects, which, in the opinion of the EMPLOYER, will not affect the commissioning of the plant), preliminary acceptance certificates shall be issued by the employer within thirty (30) days of successful completion of preliminary acceptance tests, and liquidation of the defect lists.

-

In the event of delay in completion of preliminary acceptance test and issue of preliminary acceptance certificate for reasons not attributable to the supplier for more than ninety (90) days beyond the schedule date, the supplier shall receive a “deemed preliminary acceptance certificate” (deemed PAC) to enable in supplier draw the corresponding payments. “Deemed PAC” shall, however not relieve supplier of his obligations for preliminary

acceptance tests as per contract.

Note: Supplier should warrantee supply of spares for at least 10 years. 13.2. Commissioning Successful commissioning shall mean all activities after issue of preliminary acceptance certificate up to integrated operation of plant, covered in scope of supplier and which shall include partial load/full load runs for mechanical/electrical layout and gathering of operational data, calibration

28

setting and commissioning of systems and shut down, inspection & adjustment after running of plant.

-

After the issue of preliminary acceptance certificate, start-up and commissioning of plant x in an integrated manner would be undertaken under the sole responsibility of supervisory personnel deployed by supplier. A detailed programmer of commissioning shall be drawn by the supplier 1 month in advance.

-

The employer shall, for the purpose of start-up and commissioning, provide operating personnel for normal operation, which shall work under the instructions and guidance of the supplier’s personnel.

-

Start-up and commissioning of the plant shall be taken up only when electric power system, fluid system, auxiliaries and feed materials as well as the preceding/ succeeding parts of the PLANT are ready. Supplier shall rectify the defects observed in its scope of work during commissioning period promptly.

-

During the start-up and commissioning, required adaptation, adjustment and gradual & sustained increase in production capacity is demonstrated. PLANT shall deem to have been successfully commissioned when it is able to transfer the products complying with the specifications and capacity and temperature as detailed in the supplier SPECIFICATION.

-

Results of successful commissioning shall be recorded jointly by the supplier and the employer.

-

The supplier shall arrange all measuring instruments required for successful commissioning.

-

The supplier shall take steps to liquidate all defects after which the employer shall issue Successful Commissioning Certificate.

-

On completion of Successful Commissioning and commencement of commercial production and subject to SUPPLIER's meeting the requirement as per above stated clauses, the employer shall issue Successful Commissioning Certificate within thirty (30) days.

-

The PLANT shall be taken over by the employer when Successful

-

Commissioning Certificate has been issued by the employer subject to the following: a) The supplier has supplied the fast wearing items for two (2) years normal operation and maintenance. b) The supplier has liquidated all the objections/observations, if any, contained in the Preliminary Acceptance Certificate to the satisfaction of the employer. c) All As-built drawings & documents are furnished by the supplier.

-

In the event of delay in successful commissioning and issue of Successful Commissioning Certificate due to reasons not attributable to the supplier for more than one thirty (30) days beyond the schedule date, the supplier shall receive a "Deemed Successful Commissioning Certificate" to enable the supplier draw the corresponding payments.

-

"Deemed Successful Commissioning Certificate" shall, however not relieve supplier of his obligations for Successful Commissioning as per Contract.

29

13.3. Final Acceptance Test (Performance Guarantee Test) Performance Guarantee Tests (PG Test) shall mean such, as are prescribed in contract specification as well as statutory tests, if any, to be carried out by the Supplier. After commissioning, stabilizing the plant will conduct performance/acceptance tests for all major items of equipment supplied to demonstrate that the equipment supplied is capable of achieving the performance parameters in accordance with the terms and conditions of the Employer. During testing, the use will be made of all measuring instruments, gauges, flow meters installed for the normal operation of equipment as well as special instruments and other accessories required to prove the guarantees. The guarantee tests will be conducted over a continuous period of 7 days. The guarantee tests should be performed for all sections. Supplier shall be allowed to conduct PG tests only after liquidation of all defect lists and after Supplier has satisfied the Employer that all plant and equipment/systems/instruments are stabilized and are in normal operation mode. PG tests shall be deemed to be successfully completed when: a)

Guarantee test has taken place for full test period and shall conform to the guarantee parameters

b)

Guarantee test has proceeded with short duration interruptions not exceeding a total of 8 hours(not attributable to the supplier), then the time for which The guarantee test is interrupted will be reduced from total time and average valves will be considered taking the reduced time period into account.

. If the total interruption exceeds 8 (eight) hours, then performance tests will be Stopped and subsequently repeated after rectification of defects. . If the analyses of raw materials or utility services deviate from the specification, then purchaser and supplier will consult each other to arrive at new performance Values considering effect on account of above deviation which will be mutually agreed.

. If , for reasons for which the supplier is responsible, it is not possible to achieve

30

the performance values as a whole or in part during performance test the supplier Shall be allowed to repeat the test as per the following schedule of contract document. Liquidated damages for non- fulfilment of performance guarantee parameters. In case after repeated performance guarantee tests, the supplier fails to achieve the guaranteed parameters as specified , following liquidated damages shall apply in Regard to the guaranteed parameters supplier price. Results of PG test shall be recorded jointly by Supplier and Employer. The final tests so as to demonstrate performance guarantees shall be carried out by the Supplier and Employer. The final tests so as to demonstrate performance guarantees shall be carried out by the Supplier under sole responsibility of its supervisory personnel in the presence of Employer within a reasonable period of time from the date on which the plant is successfully commissioned. These tests will be conducted uninterrupted for a period of 3 days. The test run results will be averaged arithmetically over the test period. If the result of these test not be in accordance to the contract specification, the tests shall be repeated by the Supplier within one month from the date plant has failed in PG test. In case PG tests are delayed for reasons attributable to Supplier, equipment-aging factor shall not be considered during performance Guarantee tests.

Note: If any standards about noise level, vibration and requirement of ISO 18000, 14000, etc. have not been used in this contract, the first Iranian Standards and the Second the same related International Standards should be used. All of related penalties should be considered in the Article. 13.4. Final acceptance (FAC) Final acceptance certificate (FAC) shall be issued by the Employer within ninety (90) days from the latest date when: a) Performance guarantee tests in respect of plant as a whole have been carried out and performance guarantee values achieved b) Performance of the plant has been established to be integrated with the material handling system, electric power system, fluid system and auxiliaries serving the plant. c) The Supplier has met any and all other obligations under this contract. d) Final documentation, if any, incorporating latest modifications in as-built drawings has been submitted by the Supplier in requisite copies as per contract. e) The Supplier has undertaken rectification in a definite manner for all objections/ observations mentioned in the successful commissioning certificate.

31

f)

The plant has operated normally for a period of 12 months from the date of successful commissioning certificate.

14. Spare Parts 14.0. General The objective of this specification is to define the requirements for spare parts, including:

-

First fill and 6 months operating consumable

-

Commissioning spare

-

Two years fast wearing

-

Capital (Operational) spares

-

Special tools& tackles

Note: Employer has the right to change the quantity, type and kind of spare parts.

14.1. First Fill and 6 months normal operating consumable The plant shall be supplied with the first fill and 6 months normal operating consumable materials and also sufficient for start-up, commissioning and demonstration of Performance Guarantee periods of the whole plant. The required consumable material such as, oils, grease, lubricants (including flushing oils), etc are included in the scope of supply of consumables by the Supplier. The first fill and consumable materials to be supplied by supplier

14.2. Commissioning Spares The plant shall be supplied with the required spare parts & fast wearing of the whole plant for the start-up, commissioning, demonstration of Performance Guarantee. Supplier shall take all necessary spare parts during commissioning out of stock of two years spare parts and will refill later free of charge.

14.3. Two Years spare parts Supplier should supply spare parts for 2 years of normal operation

Note: The complete set of drawings for non-standard fast wearing spare parts should be provided by SUPPLIER in CAD (DWG) format. In these drawing it should be submitted all enough information to allow further manufacturer to fabrication these parts.

14.4. Capital (Operational) spares Capital (Operational) spares include critical spare parts, which are advisable to hold operation/stock at all times because, in the event of an unexpected breakage or failure of such items, the time to repair or to replace it would incur serious loss of production.

32

Capital spare parts

14.5. Special Tools and Tackles The plant shall be supplied with the required special tools, tackles and instrument of the whole plant. The list of the special tools, tackles and instrument for the whole plant must be confirmed during the engineering phase

15. Quality Assurance & Quality Control Plan 15.1. Quality Assurance The Supplier shall institute a quality assurance system to demonstrate compliance with the requirements of the Contract. The system shall be in accordance with the details stated in the Contract. Employer /Consultant shall be entitled o audit any aspect of the system. Details of all procedures and compliance documents shall be submitted to the Employer /Consultant for approval before each design and execution stage is commended. When any document of a technical nature is issued to Employer/Consultant evidence of the prior approval by the supplier himself shall be apparent on the document itself. Quality assurance procedures shall be carried out by the Supplier at the works during manufacturing in International or local workshop. The procedures shall cover all inspection and testing of structural steel, equipment of the plant, auxiliary plant, mechanical services equipment, electrical apparatus and drives, refractory, control system, pipe work and installation materials, supplied as part of the Contract works. The procedures shall include all verification of the quality of materials and workmanship and all statutory requirements. Compliance with the quality assurance system shall not relieve the Supplier of any of his duties, obligations or responsibilities under the contract.

15.2. Quality Control and Technical Inspection 15.2.1- Definitions - Quality Inspection Categories Quality Inspection Categories are as follows: Class A: Inspection, test and test run are carried out in the presence of Employer/Consultant’s inspectors. After completion, Supplier will present an inspection record and test reports in accordance with the terms of the Contract. An inspection protocol will be signed by Supplier and Employer/Consultant to confirm the inspection. Class B: Inspection, test and test run for manufactured and/or serial parts are carried out on a random selection in the presence of Employer/Consultant’s inspectors. The remaining parts can be inspected without the presence of the Employer/Consultant. After completion, manufacturer will present to Employer/Consultant an inspection record in accordance with the terms of the Contract.

33

Class C: Manufacturer will proceed with inspection without Employer/Consultant’s participation, however, the manufacturer shall provide an inspection certificate for Employer/Consultant and the Supplier. - Codes and standards Following standards will be applied: • DIN Standard • VDE Regulation • ISO • ISIRI • IEC • Standards of Supplier’s country (which should be equal or better than above mentioned standards and also should be provided to Employer/Consultantin English) All equipment and materials will be supplied to metric units of measurement and materials codes.

15.2.2. Pre-Inspection Meeting The purpose of a pre-inspection meeting is primarily to ensure that the quality requirements are being handled satisfactorily and that all requirements in the purchase order, contract, the applicable specifications, standards, and drawings are fully understood and confirmed by all concerned parties. The pre-inspection meeting is normally held with the Supplier’s inspector and the subsupplier/manufacturer/ vendor inspector and the Employer/Consultant’s inspector, when necessary. The Supplier inspector and Employer/Consultant’s inspector shall decide the necessity and schedule of the meeting. The pre-inspection meeting is mandatory for critical items. The following items may be discussed in the pre-inspection meeting: •

Channel of communication

•

Inspection and Test Plan

•

Sub-supplier/manufacturer/ vendor Quality system

•

Area of concerns

•

Fabrication/construction sequence, etc

•

The sub-supplier/manufacturer/ vendor’s quality control program, including details of the manufacturing/construction and its sequences, witness/hold points for inspection, and the quality control system shall be studied.

The sub-supplier/manufacturer/ vendor’s quality control and inspection organization shall be checked and reviewed for its ability to retain the required quality of workmanship. Coordination procedures, such as communication channels between the parties concerned and submissions of records etc., should be clearly understood by the sub-supplier /manufacturer/ vendor at this meeting.

34

15.2.3. General The Supplier will test and inspect all equipment and material as per Technical Rules to Tender The Supplier shall carry out all tests mentioned in the specifications and as directed by Employer/Consultant, whether mentioned in the Contract Documents or not, to ensure that all materials, equipment, machineries and other prefabricated components of the Works are manufactured, fabricated and assembled in accordance with the drawings, specifications, and international standards, codes and sound engineering practice. In order to understand Supplier’s recommended sub-supplier and its inspection criteria, within 2 (two) months after Basic Design Review, Supplier should provide Employer/Consultant with the names and addresses of the sub-suppliers of Supplier’s scope of supply. When sub-contracting, the Supplier shall satisfy Employer/Consultant that a quality specialist responsible for quality together with sufficient and suitably qualified staff will be assigned to control the quality product aspects of the Contract. The Supplier shall retain responsibility for the quality control, inspection and testing activities carried out in the manufacturing works of Sub-suppliers. If Employer/Consultant considers that the proposed quality specialist and/or quality personnel is unsatisfactory or becomes unsatisfactory during the course of the Contract due to staff changes or for any other reason, the Supplier shall employ for the period of the Contract and at the Supplier’s cost an independent quality specialist and/or sufficient and suitably qualified staff approved by Employer/Consultant. The Supplier should provide the applicable standards and regulations for the materials and equipment inspection. For each equipment or system a detailed Quality Control and Testing Manual (QCTM) shall be prepared by the Supplier and submitted to Employer/Consultant for approval. The date of submission shall be after approval of detailed design drawings by Employer/Consultant and before start of construction. Employer/Consultant will review and inform the Supplier of their comments. After editing the QCTM according to Employer/Consultant comments and final approval of it by the Employer/Consultant, all the technical inspections shall be done according to this QCTM. The following documents shall be included in QCTM as minimum requirements: - List of units & drawings - Welding Procedure Specification (WPS) - Quality Control Plan (QCP) - Visual and dimensional inspection guidelines - Sandblast and painting specification If any equipment or a part of it shows defects that requires repairs, the Supplier shall not proceed to make such repair without the prior approval of Employer/Consultant. In all such cases a technical report on the repairs which need to be executed must be prepared by the Supplier and submitted to Employer/Consultant. All defective areas shall be non-destructively tested before and after repair. The documents required for the approval of the Materials, machineries and equipment, as set out in the Contract, must be delivered to Employer/Consultant in six complete sets and in such time, as to enable Employer/Consultant to perform the necessary review and checking.

35

All project material and equipment ready for delivery are subject to a visual final inspection prior to packing. Also those particular objects to be put in sealed bags, cases and crates have to pass such inspection too. The documents necessary for final inspection and release for packing shall be prepared as set out in the Contract and shall be delivered to Employer/Consultant together with the pertinent technical specifications. These documents will include but not limited to the following: • Reports on tests performed • Casting certificates/Material Certificate • Pressure testing certificate • Certificates of the pertinent testing laboratories or institutional inspection authorities. • Results of any non-destructive tests, together with the pertinent sketches and descriptions. • Reports on welder's qualifications. • Specifications of welding electrodes and methods used. • Assembly drawings of the machinery and equipment. • Detailed workshop drawings of the contract and spare parts. • Catalogues • Erection specifications and information. • Maintenance and operating manuals of Sub-Suppliers checked by the Supplier. The Supplier shall keep adequate records to enable the status of design appraisals and acceptances of certifying authorities to be assessed at any time (e.g. correspondence, details of documents submitted, approvals gained, comments received from certifying authorities, sub-order inspection requirements etc.). The inspections, tests, witnessing, verifications, acceptances, clearances, etc., carried out or issued by Employer/Consultant shall neither relieve the Supplier of its responsibilities regarding failures and defects, nor will it affect the guarantee assumed in the Contract.

15.2.4. Tests All materials, instruments and equipment for the tests shall be provided by the Supplier to the approval of Employer/Consultant. Special tests which cannot be performed at the Supplier's premises or with the equipment at the Supplier's laboratories shall be performed by qualified independent international institutions approved by Employer/Consultant. For mechanical tests and chemical analysis, test pieces shall be branded in the presence of the Supplier and Employer/Consultant and for important forgings and castings the position of the pieces shall be approved by Employer/Consultant. The type and extent of non-destructive examination at relevant stages of manufacture will be suggested by the Supplier and approved by Employer/Consultant taking into account the service for which the component is intended.

36

All NDT, DT, painting tests, etc. shall be done by qualified independent institution approved by Employer/Consultant. All the cost for these tests shall be in charge of the Supplier. Items of Plant and Equipment having a definite performance specified either in the relevant standards or specifications shall be tested for such performance in the presence of the Supplier and Employer/Consultant. Pressure/Hydro/leakage tests shall be carried out on all related components. Where practicable items of associated equipment which together comprise a complete assembly shall be assembled at the manufacturer's works and tested to prove the combined performance. Test certificates shall be supplied for all such tests. The Supplier may propose that the results of type tests be accepted as evidence of compliance with the specification. Any such proposal shall be subject to Employer/Consultant approval, for which the Supplier shall submit the relevant certificates and test data. The Supplier shall be responsible for ensuring that all tests and approvals required by statutory authorities are duly performed by an approved insurance (or other organization) authority at the Supplier’s expense.

15.2.5. Quality Inspection For all equipment, an ex-works inspection shall be carried out according to an inspection schedule worked out during basic/detail design and mentioned in Quality Control Procedure. The inspection could include following items: Visual inspection, Dimensional inspection, Material inspection, Non-destructive examination, Partial assembly examination, Complete assembly examination, Insulation test, Functional test for electrical control equipment, Functional test for individual items, etc. Three month before the actual inspection, Supplier should provide the necessary preliminary technical data and drawings for Employer/Consultant’s inspectors for reference, free of charge. Two month before the actual inspection, Supplier should provide the necessary final technical data and drawings for Employer/Consultant’s inspectors for reference, free of charge. One month before the equipment under class A will be assembled as well as the time which class B, will be available, the Supplier shall notify Employer/Consultant. The Supplier should assist Employer’s/Consultant’s inspectors in understanding International Inspection Standards mutually agreed on and in answering necessary questions concerning the inspection. In respect of the work which Employer’s/Consultant’s personnel are entitled to examine, inspect, measure and/or test (class A and B), the Supplier shall give notice to the Employer/Consultant at least two weeks before the scheduled dates for witness/action points identified in QCPs and before it is covered up, put out of sight, or packaged for storage or transport. Employer/Consultant shall then either carry out the examination, inspection, measurement or testing without unreasonable delay, or promptly give notice to the Supplier that the Employer/Consultant does not require to do so. However, it is the obligation for the Supplier to accomplish the entire inspection item strictly according to the

37

QCTM, which is confirmed by the Employer/Consultant and Supplier. All documents regarding to quality control like Test Certificates, Internal Inspection Reports, Technical Specification, Approved QCTM, Approved main drawings and shop drawings shall be prepared and available for review before the Employer/Consultant inspector attend the work for inspection. If the Supplier fails to give the notice, he shall, if and when required by the Employer/Consultant uncover the work or disassemble it and thereafter reinstate and make good and perform the specific test /inspection, all at the Supplier’s cost. The Employer’s/Consultant’s personnel shall at all reasonable times: • Have full access to all parts of the Site and to all places from which materials are being obtained, and • During production, manufacture and construction (at the Site and, to the extent specified in the contract, elsewhere), be entitled to examine, inspect, measure and test the materials ,any kind of construction ,fabrication ,procurement ,workmanship, and to check the progress of manufacture of Plant. The Supplier shall give the Employer’s/ Consultant’s personnel full opportunity to carry out these activities, including providing access, facilities, permissions and safety equipment. The Supplier and his Sub-Suppliers shall provide Employer/Consultant free of charge adequate office space, secretarial assistance and telecommunication services during the execution of the inspection activities. Also board and lodging, local transportation and medical insurance covering hospitalisation and treatment of Employer inspectors are at the Supplier’s cost. Employer will bear for its inspector the costs such as round international trip tickets, hotels, local accommodation, salaries and personal expenses and telephone calls. It would be mentioned that the cost such as: internal air tickets and transferring to factory and insurance and visa will be carried out by contractor.

15.2.6. Reports The Supplier shall provide reports of all visits made by his quality assurance personnel and any other inspecting engineers appointed and acting on his behalf. The Supplier shall fully document all quality assurance checks, inspections and tests carried out in his own works and those of all Sub-Suppliers. Four copies of all such reports and certificates shall be forwarded to Employer/Consultant within one week of testing. Any discovered damage, defects or rejections which in the Supplier's view may prevent satisfactory completion of the Contract Works, or cause delays to program shall be advised to Employer/Consultant by e-mail or facsimile and be confirmed by written report within one week. The Supplier shall submit to Employer/Consultant, at intervals of not more than four weeks, a summary of all quality control, inspection and testing activities which have taken place in the previous four weeks.

15.2.7. Final book

38

The Supplier shall compile a final data book progressively during the execution of the Contract, which shall include but not limited to the following: • Index • P/O or Contract No. • Basic engineering drawings • As-built drawings • Detailed catalogues • Technical specification • Record of identification marks • Heat treatment charts • Material test certificate • Inspection and test reports • Procedures, procedure qualifications and operator qualifications • NDT certificates • Master quality plans • Rework/repair details • Non – conformance reports • List of recommended spare parts /consumables • List of recommended special tools and tackles for erection and operation and maintenance • List of lubricants and chemicals including quantity and time schedule of initial fill • Storage manual • Commissioning, operation and maintenance manuals The final book shall be submitted to the Employer/Consultant at the time of equipment shipment to the site.

15.2.8. Draft Quality Control and Quality Assurance Procedure Within two weeks of

the

effectiveness

of

Contract

the

Supplier

shall

submit

to

the

Employer/Consultant for approval a draft procedure of quality assurance, quality control, inspection and testing activities which he proposes to perform, together with a program indicating when these activities are to be carried out. The program of inspection and testing shall be related to the preliminary program of Plant design, manufacture, erection and Tests on Completion. Individual 39

quality assurance procedures shall be proposed for any specialized item of Plant but standardized procedures may be proposed for common items such as castings, forging, fabrications, structural steel, fans, pumps, pipe work, valves, tanks, drive units, ducting, compressors, couplings, bearings, motors, conveyors, switchgear, control gear, batteries, transformers and instruments. The Employer/Consultant shall have the right to modify or complete the draft quality control procedure whenever the modifications are supported by the Contract Documents.

15.2.9. Detailed Quality Control and Quality Assurance Procedure Within two months of effectiveness of Contract and following approval of the draft procedure by the Employer/Consultant, the Supplier shall submit to the Employer/Consultant six copies of the agreed detailed quality assurance procedure and a detailed program of the inspections and testing to be carried out for approval. This program shall conform to general Time Schedule of the Contract. In order to achieve a uniformity of quality assurance procedures, inspection and testing throughout all aspects of the Contract Works from design to commissioning, the procedure shall be issued by the Supplier to all members of his quality assurance organization, to all Sub-Suppliers and to all supervising engineers. The document shall also be issued by the Supplier to the Employer/Consultant carrying out inspection and surveillance. The Supplier is responsible for submitting reviewed QCPs/QAPs from its Sub-Suppliers to Employer/Consultant for approval. The procedure shall not be altered without prior agreement by the Employer/Consultant but the Supplier shall maintain a complete list of recipients of all issues of the procedure, in order to ensure correct updating by revisions, which may be so approved. Work identified on a QCP/QAP shall proceed only when the document has been approved by Employer/Consultant.

15.2.10. Additional/Alternative Tests/Inspection The Employer/Consultant may direct the Supplier to perform additional or alternative tests/inspections for specific components. Costs of such tests/inspections shall be on the Employer account if the product is proven acceptable. Costs of such tests/inspection shall be on the Supplier’s account if the product is proven to be not in accordance with the Contract requirements or not suitable for intended use. 15.2.11. Rejection If, as a result of an examination, inspection, measurement or testing, any plant, materials, design or workmanship is found to be defective or otherwise not in accordance with the Contract, Employer/Consultant may reject the plant, materials, design or workmanship by given notice to the Supplier, with reasons. The Supplier shall then promptly make good the defect and ensure that the rejected item complies with the Contract. 40

If Employer/Consultant requires this plant, materials, design or workmanship to be tested, the tests shall be repeated under the same terms and conditions. If the rejection and retesting cause the Employer to incur additional costs, the Supplier shall pay these costs to Employer.

15.2.12. Remedial Work Notwithstanding any pervious test or certification, Employer/Consultant may instruct the supplier to: (a) Remove from the site and replace any plant or materials which is not in accordance with the contract, (b) Remove and re-execute any other work which is not in accordance with the contract, and (c) Execute any work which is urgently required for the safety of the works, whether because of an accident, unforeseeable event or otherwise. Additional costs arising from activities associated with products proven to be defective, non– conforming or late with respect to agreed delivery times shall be on the Supplier’s account.

15.3. Quality Management System The supplier shall comply with all requirements of the latest revision of ISO 9001 "Quality Management Systems" unless otherwise agreed by the Employer/Consultant Should the Supplier or any of the proposed sub-suppliers not comply with ISO 9001 at the time of tender, a contract may be awarded subject to a written undertaking by the Supplier to enhance his own and/or sub-supplier’s Quality Management System to the satisfaction of the Employer prior to commencement of manufacture in terms of the Contract.

15.4. Surveillance Surveillance will be carried out by a Third Party Inspection (TPI) Company which has the international authorization or Institute of Standards and Industrial Research of Iran (ISIRI) authorization and with approval of Employer Surveillance three months’ schedules should be sent to TPI Company. Surveillance will start after final inspection call which must be sent to the TPI Company at least two weeks before inspection date. In this stage the Technical Certificate (TC) or Waive Letter which is approved by Employer, could have been received for the mentioned Equipment. Surveyor will inspect the cargo and will issue the Inspection Report of Packing (IRP) and will transfer to Employer to get the delivery permission and will issue the Certificate of Inspection (COI) after loading.

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15.5. Technical Assistance The Supplier scope of work for Technical assistance in quality control field is as follows: a) Technical assistance of all suppliers is in scope of Supplier. b) Cost of technical assistance will be considered in supplying equipment. c) Preparation of required standard and specification for designing, manufacturing and construction is in Supplier scope of supply.

15.6. Tender Information The Supplier is also required to supply necessary information to enable Employer/Consultant to make assessment of quality control, inspection and testing policies of the Supplier. Also certain minimum requirements in this respect have been laid down here. The Supplier shall submit with his Tender Proposal: • A description of the quality assurance procedure, • A description of Quality control, inspection and testing procedure The latter description shall include non-destructive testing (NDT) facilities, material testing, control of critical welding operations, material classifications and identification and all test facilities. The Supplier shall submit with his tender an example of a typical quality control plan currently in use in the Supplier's manufacturing works with an organization chart showing the numbers of personnel and qualifications which he intends to adopt for the Contract Works.

16. Specification for packing, Marking and forwarding 16.1. General This section covers the general requirements for the packing, marking and forwarding of all equipment and materials required for this project. It represents the minimum requirements for packaging of material and equipment for handling, ocean shipment, road haulage and extended storage in the Site climatic conditions. In all instances it is the responsibility of the Supplier to ensure that the packaging is adequate for the consignment involved during shipping and storage and able to withstand the extremely rough handling to which it will be subjected. 16.2 PACKING 16.2.1. General This section sets certain requirement as a minimum. Compliance with the requirements of this section shall not be considered a limiting clause relieving Supplier of any obligations undertaken in the

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Contract. All equipment and materials shall be carefully packed for transport and designed to protect the contents from damage due to impact, crushing or vibration, environmental conditions, pilferage or attack by micro-organisms, insects, rodent, etc. The type of packing shall be determined by the contents which requires protection and can range from hermetically sealed metal containers to open crates. Efforts shall be made to keep the overall volume and weight to a minimum. The design must be such to be capable of withstanding a long period of shipment (possibly in excess of 8 months) and storage for periods as long as three years in hot summer and cold winter climate with occasional storm and extremely rough handling. The packing can be carried out in compliance with the following typologies: •

Wooden cases or cases coated with a phenolic plywood

•

Crates featuring non-continuous wooden panels

•

Bundles ties with wooden or iron clamps with threaded tie rods.

•

Special types of packaging that keep the goods off the floor

•

Goods that have not been packed

The exterior pack shall consist of the most practical utilization of export packing materials in combination with interior cushioning, blocking, bracing and preserving to provide a package which either permits shocks to be absorbed and relieved, or distributes and transforms the forces in such a manner that the container and its contents are able to withstand them without damage. In the case of material treated with protective coatings, the protection expiration date shall be indicated. In addition all other instructions for correct preservations of the material and/or equipment are to be attached to the package, or clearly identified with a special code stenciled on. Grab hooks may be permitted for cases weighing up to 1000 kg gross. Cases shall therefore be able to support the full weight of the package when handled in this manner and grabbing points shall be clearly marked on the case. The weights and unit dimensions of the packages shall take into account the requirement of any special conditions affecting shipment or transport by road and rail in Iran. The packing procedure and shipping protection shall be subject to inspection by the Employer/Inspector before equipment is put into a case/crate, and again before a case/crate is closed. For exercising inspection rights, advance notice and obligations of Supplier, as related to shipping protection and marking shall be as specified in the Contract. The Employer/Inspector will sign the packing list as evidence of conformity, but this signing will not release Supplier from any of his obligations under the Contract. When necessary, equipment shall be bolted to case/crate base. Bulk items shall be banded or otherwise unitized and fastened to the case/crate. Shock absorbing media such as felt layers shall be placed between the equipment base and the case/crate for rotating machinery and large electrical equipment.

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Fragile items shall be wrapped with efficient cushioning material or floated in excelsior. When several items are packed in the same case/crate, they shall be packed in a manner which will prevent one damaging another. Wood spacers shall be used between parts weighing more than 20kg. In all cases items shall be nested or packed to reduce volume as much as possible. Waste space within a container is a source of weakness and increases shipping cost. Hygroscopic packaging materials, if used, shall be dry and every effort shall be made to avoid trapped water in equipment to be packed. The packing has to be of such design that damages will occur neither on the packed goods nor on the packing as such by tilting, displacing, swinging, vibrating, lifting, escaping, etc. The designation and description of the package content must be in complete and exact agreement with the packing lists. All mechanical, piping and instrument part of an equipment which should be connected together to make a mechanical apparatus or part of production line should be contained in one pack or several pack observing proper addressing and numbering. These observations make ease to collect different part of equipment with low risk of missing or shortage of parts during unpacking. During the construction of the packages, the dimensions must remain according to rules of “Ministry of roads and transportation of Iran” otherwise extra cost shall be charged by Supplier.

16.2.2. Temporary Protection of Surfaces All surfaces of goods which may be corroded or attacked by fungi under the influence of moisture and high temperatures (which reach above 50 °C) shall be treated with reliable inhibitive chemicals. Exposed metal surfaces of equipment shall be protected from corrosion by covering with an easily removable moisture barrier which shall last throughout the period of shipment and storage, prior to being put into use. The protective coating shall be applied to clean, moisture free surfaces. The choice of the protective coating depends on the material to be protected and shall be safe to handle and easily removable by the application of common solvents or other simple means, such as wiping or stripping. The details of the treatment used and the method of removal of the protective coating shall be described and included with the other information to be packed with the shipment. Wherever possible, the protective coating shall be covered with a moisture proof barrier, such as PVC or polythene and suitably sealed. Deck loaded items shall be painted as per specification for protective coatings. For material not shipped in closed cases, (i.e. vessels) all openings shall be sealed. The needed openings shall have a screw cap.

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Flanged openings shall have gaskets and metal plate covers bolted to flange. Non-flanged opening may be soundly plugged or plastic wrap sealed and banded. Bagged desiccant shall be fastened inside each sealed item. Pipes shall be cleaned internally and their inside surfaces be protected by a corrosion inhibitor. The pipe ends shall be plugged (if required) to prevent ingress of water and dirt during shipment and storage.

16.2.3. Vapour Barriers and Moisture Proofing Due to the long shipment and storage periods, any material or equipment subjected to deterioration due to exposure to moisture shall be suitably protected. Delicate equipment, such as switchgear, control gear, instrumentation, communications equipment and precision mechanical equipment shall be sealed in robust, transparent polythene envelopes with a suitable desiccant. All sealing shall be done by welding. Openings in electric motors, generators and other electrical equipment shall be sealed with waterproof tape or in some equally efficient manner. Protective greaseproof paper shall be inserted between the brushes and armatures of motors and generators. The use of PVC or polythene film of 0.25 mm minimum thickness is recommended for vapor barrier and protective wraps. The insides of all packing cases shall be lined with an approved seaworthy packing paper or plastic film capable of withstanding great changes of temperature. This shall be placed between the sheathing and the frame members. Wherever possible, equipment shall be wrapped with a rust inhibitive paper with the moisture repellent face towards the packing case and the moisture absorbent face towards the packed items. The lid of the packing case shall be covered with a layer of bituminous felt to prevent water seepage into the case. Sufficient quantity of a suitable desiccant shall be placed within the packaging to ensure that the relative humidity of the air within the vapour barrier does not exceed approximately 35% throughout the required period of shipping and storage. Equipment and materials which are extra sensitive to humidity shall have additional quantities of desiccant to maintain the relative humidity at the lower value required for the article packed. The desiccants used for packaging should preferably be in granular or tablet form and shall remain solid and dry to the touch and suffer little or no disintegration throughout the performance of its function. The materials shall be such that the absorption of moisture is not accompanied by chemical changes that will cause it to corrode or otherwise damage its container or the article packed. It shall not produce a liquid or gas or a significant rise in temperature.

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The desiccant, in perfect condition regarding moisture absorbing capacity, shall be placed within the vapour barrier of the equipment packaging in a suitable container. The container shall be such that moisture can easily reach the desiccant. Pumps, compressors, electrical cabinets and similar items which may be sealed prior to packing shall have bagged desiccant fastened inside the enclosed space in addition to the desiccant for the case packing. 16.2.4. Wooden Cases Lumber shall be sound and well-seasoned of pine, poplar or fir tree, without knots or defects which might reduce board resistance. All nails shall be either one of the following types: •

Cement coated nails

•

Ringed nails

•

Screw nails

For plywood cement coated staples may be used. Plywood shall be best quality 3 or 5 ply not less than 9 mm thick. All lumber dimensions indicated are minimum dimensions subject to standard tolerances (average of 5%). Cases with gross weight over 12000 kg require special design of cases and skids, subject to agreement with the Employer/Inspector. 16.2.4.1. Wooden Cases up to 300 kg Gross Weight Case boards shall have a nominal thickness of 25 milli-meters at least, and shall be joined by guides at least 11 milli-meters deep. Board width shall not exceed 250 milli-meters, nor be less than 120 milli-meters. When their contents allow it may be built without bottom beams, but with fastening crosspieces of25 milli-meters minimum thickness on sidewalls and of 40 milli-meters minimum thickness on the bottom, applied at about every meter of case length. Steel strapping shall be in accordance with Para 8.2.4.3.8.

16.2.4.2. Wooden Cases More Than 300 kg Gross Weight All cases of this group shall satisfy the following requirements: •

All cases of this group to be skidded and framed.

•

Design to follow detailed instructions given under sub-clause 8.2.4.3. These instructions are minimum requirements.

•

Design of cases of excessive weight or dimensions is to be discussed with the Employer/Engineer prior to construction. 46

•

Each bearing surface of machinery or equipment shall rest over a skid member and bolts securing equipment to skid shall pass through a skid member. Lag screws are not acceptable for this purpose.

•

All cases exceeding appr. 1 ton gross weight shall be equipped with angle irons and with stirrups on hoisting points.

16.2.4.3. Instructions for the Construction of Wooden Cases 16.2.4.3.1. Skids and Headers Cases shall be fitted with skids parallel to the case longitudinal axis and adequately sized according to the weight, load distribution and length. (Figure 1) The skids shall preferably be placed at 800 to 1000 mm distance from each other. They shall have bevelled ends at 45º to facilitate the insertion of lifting ropes. Minimum cross section of skids and headers are indicated in table 1. Headers at both ends of case shall be bolted perpendicular to skids. Table1. Minimum Cross Section of Skids and Headers Length of Case 2m Gross Weight kg

4m

8m

Minimum Number of Skids 2

3

4

a×h

a×h

a×h

1500

100×100mm

100×100mm

100×100mm

3000

100×150mm

150×150mm

150×150mm

6000

150×150mm

150×200mm

150×200mm

12000

200×200mm

200×250mm

200×250mm

16.2.4.3.2. Under beams Beneath the skids, the under beams (45 mm thick) shall be fitted so as to frame the lifting ropes; their position will depend on the center of gravity of the case.

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16.2.4.3.3. Top Joists Top joists shall be fitted at center to center distance of 800 mm. Their cross section shall be within the limits indicated below:

Weight of Case (kg)

Top Joists Section (a×h)

Up to 6000

50×100 mm

Over 6000

100×100 mm

16.2.4.3.4. Side Walls a) Side Wall Struts Struts are to be fitted between framing and placed beneath the top joists. Cross section of struts shall be equal to joist cross section. (Figure 1) b) Side Wall Framing and Diagonals Framing shall be placed at all edges of case. Diagonals shall be fitted between framing and struts. Minimum cross sections of framing and diagonals are 50×100 mm. 16.2.4.3.5. Bottom Construction Width of lumber shall be 120 -250 mm. Thickness of lumber depending upon the gross weight of the case shall be as follows: -Up to 1500 kg

Thickness = 30 mm

-Up to 3000 kg

Thickness = 40 mm

-Over 3001 kg

Thickness = 50 mm

Case over 3000 Kg need additional load bearing floor members where load is concentrated.

16.2.4.3.6. Sheathing (Side-Walls. Top) Width of lumber used shall be 120 -250 mm. Thickness shall be as specified below: -Up to 3000 kg

Thickness = 20 mm

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-Up to 8000 kg

Thickness = 25 mm

-Over 8000 kg

Thickness = 30 mm

16.2.4.3.7. Plywood Instead of sheathing, case side-wall and top may also be made of phenol bonded Douglas fir marine plywood. Thickness shall be minimum half of sheathing thickness. All other regulations apply unchanged.

16.2.4.3.8. Steel Strapping Steel strapping shall be applied to all boxes/crates up to 3000 kg. Space between straps should not be more than 1000 mm and with not less than 2 bands per box, and the end straps not more than 100 mm from end of box. Straps for case gross weight of up to 1000 kg shall be min. 20 mm wide, and for case gross weight above 1000 kg and up to 3000 kg shall be min. 30 mm wide, applied with a stretching tool and secured with crimped steel seals.

16.2.4.3.9. Inspection Door (Window) All wooden cases above 4 m length or 1.5 m height shall have the inspection door. The dimension of inspection door is as follows: Length

350~400mm

Width/Height

250~350mm

Inspection door shall be located at the side wall or top of wooden case. The numbers of inspection door are as follows: Length of Case

Number of Inspection Door

4m≤L<6m

1

6≤L<8m

2

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16.2.4.3.10- Cover sheathing For the cases, the roof sheathing may be made with: •

Boards mounted transversally to the longitudinal axis of the cases by placing a sheet of pressed cardboard before the cover support (thickness equal to 5 mm) that supports the part of the polythene sheet in excess of 10 cm surrounding the perimeter (Figure 2)

•

Multilayer panels, the sheet to which the bearing frames must be fixed to.

The external fibre must be oriented so as to utilize the maximum strength (external fibres transversally to the longitudinal axis of the case). Both boards and multilayer panels must have the edge flushed with the wall sheathing (Figure 3) The crate roof sheathing is made of boards spaced at a distance equal to the width of a board arranged transversally to the longitudinal axis of the crates and nailed to the bearing frame (Figure 4)

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16.2.4.3.11- External Protections and Reinforcements a) Rigid vertical reinforcement Reinforcing brackets must be nailed along the vertical comers of the cases and crates, according to figure 5. The brackets must be placed at the longitudinal upper, lower and intermediate (if provided) joists, unless special cases.

b) Upper border reinforcement For containers with a gross weight equal to 2000 kg or more, the part of the edge which may be damaged by the wire rope in the upper part of the container must be protected with steel angles built and positioned as per figure 5 and suitable dimensioned and fastened.

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c) Lower border reinforcement For containers with a gross weight equal to 2000kg or more, the part of the edge at the under beams which may be damaged by the wire rope in the upper part of the container must be protected with reinforcing brackets made and placed as illustrated by figure 5 and suitably sized and fixed.

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16.2.5. Steel Cases and Drums Steel cases shall be used for the protection of materials and equipment particularly vulnerable to damage, loss or pilferage during transport and storage. Precautions shall be taken to cushion, block, brace and preserve the materials within the cases. Typical items for packing in this manner would be instruments, refractory ceramics and other fragile equipment. The steel cases and drums shall be non-returnable.

16.2.6. Case for refractories Refractories shall be packed in totally enclosed cases designed to protect their contents. Cases of refractories will be stacked a maximum of 5m high during storage at Site and shall therefore, be suitable for handling by fork-lift truck or crane. The gross weight of a case shall not exceed 3000kg. Refractory cements in small drums or bags shall also be packed in totally enclosed cases for additional protection and convenience of handling.

16.2.7. Open Crates Open crates shall be used for physical protection of light bulky items. These items shall be securely fastened to a skid and completely immobilized by means of wooden chocks and steel bracing. The item shall be restrained only by the skid and attached bracing and shall not require additional support from protective box. Additional slats will be provided as necessary for anchoring material, for minimizing pilferage.

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16.2.8. Lead Lined packaging Where radio-active equipment or isotopes are to be shipped, they shall be encased in lead lined packaging in accordance with the Intergovernmental Marine Consultative Organization of UN (IMCO) International Maritime Dangerous Goods Code. In addition, air freight shipments shall be in accordance with the International Air Transport Association (lATA) restricted articles regulations.

16.2.9. Bagged Items Materials normally packed in bags for shipment shall also be packed in cases for extra protection during handling (see Section 8.3).

16.2.10. Pallets Pallets, where permitted, shall have a skid base and decking of lumber with the thickness and quality as specified for cases. Material shipped on pallets shall be positioned with blocks nailed to the decking, and anchored with steel bands. The size of the pallet shall be such that the whole surface is used, but in no case overhang shall be permitted. Pallet should be constructed to permit stacking where possible.

16.2.11. Bundles Packing in bundles applies only for structural steel and pipes. Bundles shall be arranged according to the length to avoid their distortion when they are slung. Units shall be strapped at a maximum spacing of 1200 mm and shall not exceed 5000 kg in weight. Bundles must be marked by means of at least three indestructible metal tags and secured with wire of minimum 3 mm diameter. The information on the tags must include, in addition to the relevant requirements, the total number of items contained in each bundle. Such tags are to be of minimum 300mm x 450 mm. The bundle components must have a uniform shape and cross dimensions so as to prevent their slipping out during transport (Figure 6) 16.2.12. Loose Material and equipment, which cannot be packed due to their size and weight, may be shipped loose. These cases are to be discussed and agreed with Employer/Inspector. Provisions shall be made for 54

safe lifting by ropes.

16.2.13. Material and Equipment 16.2.13.1. Columns and Cylindrical shaped equipment They shall be packed with wooden saddles, placed in such a way as to reduce height from the ground to a minimum, fitted with steel ties and stiffening braces. If the equipment allows it, counter saddles shall be placed on the upper part, so as to be able to place other loads on top. The distance between one saddle and another shall be determined in each individual case, depending on equipment features and on road transport requirements. 16.2.13.2. Metal Structures. Structural Steel and Prefabricated Elements Bearing resisting, non-deformable structures shall be gathered in bundles. Other metal structures, plates and sheets if not otherwise specified, shall be suitably grouped together after bracing the various items so as to ensure proper solidity. Obviously such bracing operations must not reduce in any way the soundness of functionality of the items to be forwarded. Prefabricated structures, if their shape is such that they cannot be grouped in bundles, shall be packed in crates. Provision shall be made to prevent individual pieces from moving in a longitudinal direction. Proper nesting required to minimize shipping volume. 16.2.13.3. Structures Subject to Damage Structural fabrications, except as included above with projections subject to damage or impact, or with shaped unsuited to stacking and bulk materials shall be enclosed in skidded open crates.

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16.2.13.4. Flanges, Fittings, Bolts and Nuts Small parts, such as nuts, bolts, washers, small machine parts and similar items shall be corrosion protected, put into sealed plastic bags, marked for identification and packed into a drum or box and be included in larger container. 16.2.13.5. Pipes Galvanized or carbon steel tarred pipes, from 60 to 200 mm diameter shall be packed into squared bundles, easy to handle and store. For bundles refer to item 8.2.11. Pipes of larger diameter shall be shipped individually. All pipes shall be protected at their ends. Threaded pipes shall be protected by caps. Stainless steel, aluminium and copper pipes shall always be packed in crates. Different sizes of pipes shall not be nested without Employer/Inspector approval. 16.2.13.6. Machinery and Equipment (Including Valves) They shall be packed in wooden cases. All moving parts inside these units shall be firmly secured to the main structures. When equipment such as control valves, control panels, etc., are subject to damage caused by high frequency or high intensity mechanical stresses, they will be protected by packing which ensure a sufficient springing. 16.2.13.7. Electric Cables and Ropes Spools for cables, ropes and copper pipes, built in compliance with standing rules, shall be sound, new, waterproofed and closed by wooden staves nailed into the flanges and held by at least two turns of steel strap. 16.2.13.8. Control. Automation and Instruments The main instruments, control and automation items and the switchboards that may be damaged during transport and handling or subject to deterioration during storage must be supplied and assembled separately, marked in order to facilitate the assembling on site, protected against shocks and vibrations, packed in wooden cases and protected with a barrier bag. 16.2.13.9- Beams for EOT Cranes and Heavy Structural Steel Works Prefabricated structural components featuring large dimensions and weight may be considered a package and no type of protection is foreseen or required. (Figure 7) Each case must be considered individually, the parts that protrude must be locally protected against collisions. In any case, the integrity of the delicate components must be kept-in mind (Figure 7).

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16.2.13.10. Spare Parts Spare parts always shall be packed into separate cases, and where not large enough shall be enclosed in another case or crate.

16.3. MARKING AND TAGGING Instruction plates and identification nameplates shall be permanently attached to each main or auxiliary item of material and equipment in an adequate position. These plates shall be engraved with the manufacturer's name and serial number, together with details of the loading conditions under which the item of plant has been designed to operate. In addition to the manufacturer's rating plate, each individual piece of equipment shall have fitted thereon in a permanent position a nameplate bearing the functional description in English and system reference. These plates shall have complete information and information of those shall be approved by Employer When equipment is disassembled for shipment, or components are fabricated without assembly, each piece must be adequately identified for ease of assembly at site. Match-markings identical for each side of the equipment separation shall be used. All match- marks used shall appear on one or more drawings, which shall be enclosed with the shipment as described herein. Part-identification shall be paint stencilled conspicuously on large pieces of equipment. Small parts shall have a metal tag, wired (only for parts shipped in boxes), or tack welded in place, with identification stamped or etched. Bundles such as pipe and steel shapes shall have markings applied on metal plates which shall be securely fastened to the bundle by wire or steel bands. Paper or cloth tags shall not be used. 57

The Supplier has to ensure that for all material and equipment the same identification system will be used. 16.4. Shipment 16.4.1. General Material and equipment shall be shipped as below deck cargo. However, excessively bulky or long items such as structural steel, crane bridges, and vessels may be shipped as deck cargo. Normal weight limitation for shipping packaged or crated material and equipment in boxes is 20 tones. Larger and heavier parts can be shipped but special arrangements must be made in advance with Employer/Inspector. 16.4.2. Air Freight Where consignments is to be shipped air freight, attention should be paid to reducing the weight of the packaging and case. However, this reduction in weight shall in no way detract from the robustness of the case nor its ability to withstand the rough handling it will receive. Consignments shall comply with the regulations of the International Air Transport Association (IATA). 16.4.3. Special Lifting Devices Spreader bars or special lifting devices shall be furnished free of charge by the Supplier for each package which cannot be lifted solely with slings. Where spreader bars or special lifting devices are required, each shipment of equipment shall contain a separate box with these devices. The box shall have its own Bill of Lading with special instructions that it be opened at the port of disembarkation. In addition, detailed instructions shall be available on how to use the lifting devices. Supplier will send instructions to the receiving port to request that the box be opened and the lifting devices used in accordance with the Supplier’s instructions. Devices shall be selected based on using only one crane for a lift.

16.5. REJECTION Material or equipment or parts thereof damaged during shipment because of improper protection or packing shall be subject to rejection and shall be replaced by the Supplier free of charge to Employer

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17. Instruction of Submission of Drawing and Document The following drawings and documents concerning whole unit plant shall be submitted by the Supplier. All computerized files of drawings prepared in ACAD (Dwg.) shall be submitted by Supplier in CD (with extension of “Dwg.” ) in two sets along with 6 prints of each original drawing, specification, bill of materials etc.

Note: The employer's/consultant's approval shall not remove the supplier responsibility. In any case, the responsibility of the whole project is under the supplier scope of work.

17.1. Basic engineering (for approval) 17.1.1. Plot plan/lay out drawings, general arrangement (GA) drawings, showing battery limits

and plans of all units and facilities including requirements of utilities and other parameters at battery limits. 17.1.2. Process engineering assumptions/basic data design basis (Process design criteria,

Utilities specifications, Product specification and Test method, yields,...) and production plan. 17.1.3. Process flow sheets with operating conditions, flow rates, composition, temperature,

pressure… 17.1.4. Material and balance sheet. 17.1.5. Utility Data, Summary and Diagrams

Utility data, summary and diagrams including all necessary and sufficient information, data and specification and detailed description, shall be provided individually for each and all of the PROCESS UNITS/UNITS. 17.1.6. Process description. 17.1.7. Basic control schemes and interlocking requirements to have safe and efficient

operation. 17.1.8. Requirement of chemicals with physical and chemical properties and safety

information. 17.1.9. Specifications, properties and consumption figures of all adsorbents, solvent,

chemicals and consumables including three proposed names and addresses of the mail, and permanent suppliers for each item. 17.1.10. Hot and cold insulation specifications. 17.1.11. P&ID diagrams with line size, material specification, insulation requirement, equipment

elevations, line slopes, requirement of vents and drains, instruments, tracing requirement, Tower & Vertical Drum minimum elevations from ground, etc. for process and utility lines. 17.1.12. List of equipment with specification. 17.1.13. Process data sheets for all equipment. 17.1.14. Piping material specifications indicating pipe classes, pipe materials, flange ratings,

gasket types, valve types, etc. including pipe sizing calculations. 59

17.1.15. Line list and valve list. 17.1.16. Heat load calculations for air conditioning, ventilation and cooling water system. 17.1.17. Design calculations for stacks. 17.1.18. Utility block diagrams. 17.1.19. GA. & shop layout including cross-sections for shop/systems/services and Equipment

layout. 17.1.20. Design criteria, GA. and layout drawings for pipe work and duct work. 17.1.21. Equipment list and motor list. 17.1.22. List of bought out items and vendor list. 17.1.23. Civil design and drawings 17.1.24. Quality assurance plan for all equipment. 17.1.25. Water balance diagram. 17.1.26. Calculations for thermal and hydraulic regimes. 17.1.27. Process design calculations for all equipment. 17.1.28. Mechanical design calculations for all equipment. 17.1.29. Brickwork expansion calculations. 17.1.30. Piping and pump sizing calculations. 17.1.31. Diameter, length/height, material specifications, shell thickness of all fabricated

equipment. 17.1.32. Norms for providing reserve/standby units. 17.1.33. Pipe sizing calculations. 17.1.34. Pressure drop calculassions. 17.1.35. Unit Wise lay-out drawings. 17.1.36. Battery limits definitions and conditions for various streams coining to and leaving of

each individual PROCESS UNIT and UNIT/PLANT. 17.1.37. Codes and Standards. 17.1.38. Flow diagrams including: Process flow diagrams, Block flow diagrams, Utility flow

diagram etc. 17.1.39. Instrumentation

The following documents shall be compiled in ESD books under the same numbers and titles: I. Control philosophy description and drawing: explaining and showing the concept of DCS/PLC/ESD, F & G, local panels and packages control system regarding design basis and monitoring/control, remote/local, master/slave, dedicated/shared systems aspects, start-up location, systems location and interconnection. II. Advanced control manual, if any: including all necessary information and details such as control strategies descriptions, mathematical analysis and equations with definition, range and scaling of parameters, flowcharts, diagrams to enable the detailed engineering supplier and the DCS vendor to develop and implement the advanced/special control in DCS.

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III. Specification for DCS/PLC/ESD/F & G. IV. Specification for instrumentation including fixed instruments (such as but not limited to

transmitters, cables, earthing, etc.) V. a) Cause and effect diagrams show electrical and instrument interlocking and trip

requirement. b) Sequence and interlock (normal and safety) description as well as simplified logic diagram/flow charts according to IEC 61131.3 VI. Preliminary alarm and trip set points. VII. List and specification for special systems/instruments and requirements. VIII. Concept of gas monitoring system (excluded). IX. Electrical power and air consumption. X. Control room general information regarding HVAC, fire-fighting systems, etc. XI. Preliminary control room layout.

a) Preliminary console front arrangement b) Risk analysis documents with respect to OHSAS 18001 (latest version). XII. Basis requirements for DCS configuration: including special displays, grouping for displays,

reports, etc. XIII. Instrument index including tag no's, service, process conditions, type, size, range,

alarm/trip set points, P & ID no., reference to other documents etc. XIV. DCS/PLC/ESD/F & G and I/O summary XV. Instrument data sheets providing the following information.

a) Tag number b) Name c) Service d) Equipment or line number e) P & ID number f) All data which is necessary for sizing, selection and specifying the instrument such as: Stream data in min., normal and max. or other specific operating conditions (to ensure proper range ability reading and control), Vaporization across valves, sealing, purging or flushing requirements including any special process design considerations such as pour

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point, Consideration and recommendation regarding explosion, corrosion/erosion effect, toxicity and suspended particles of process medium,

Response time, Leakage class,

Accuracy (according to process requirements), etc. g) Type of instrument (principle of measurement code) h) Preliminary size and range i) Material of construction j) Impulse line and instrument casing heating/insulation requirement. XVI. Relief valve, rupture disk, breather valve summary. A summary shall be provided of the

loads front each relief device for each emergency condition under which the relief valve opens, e.g. fire, power failure (and other utility), blocked-in condition, etc. Relief and flow data summary sheets shall be provided. For all safety relief valves, inlet and outlet isolating valves shall be provided and shown in all respective drawings such as P & ID's.

17.1.44. Electrical General electrical specifications will provide sufficient information for detailed engineering and shall include the following: 1.

Specifications of normal and emergency power supply and electrical installation.

2.

Single line diagram to be used as the basis for detail engineering.

3.

Requirement of information for: a) Interlocking method with instrumentation system. b) Lighting system. c) Electrical consumers with indication of estimated power consumption except illumination. d) Consumers requiring emergency power supply and duration of it.

4. Energy requirement of PROCESS UNITS/UNITS in kilowatt hours per TON of PRODUCT and the total expected power (kw) requirement with details of high/medium voltage and low voltage loads. 5. Implications of power failure and recommended PLANT's emergency supply scheme for all types of electrical loads which require emergency power. 6. List of drives requiring emergency power feed along with their power consumption. 7. Any specific requirement for lightning protection, where applicable.

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8. Main specifications of critical drives/variable speed drives and their controls (to be added in equipment data sheets). 9. On uninterrupted power supply system (UPS) required and the following details shall be provided. a) Total load, b) Reacted voltage and permissible variation. Duration of UPS system shall be designed, c) Step load/permissible voltage dip., d) In-rush current in worst case, e) Load power factor. 10. Any specific requirement of type/material of conductor to be used for grounding, (if applicable). 11. Details of the preventive measures or means to be furnished for type of cables and their insulation cover, (if applicable). 12. List of drive requiring acceleration features to ensure faster start-up and/or to minimize PLANT shutdown time in case of process disturbances due to momentary voltage dip or brief interruption (5-10 sec.) in normal power supply. 13. Submission of motor list.

17.1.45. Operating manual The operating guide will include an outline of start-up, shut down and alternative operations. It will also indicate emergency procedures covering utility failures and major operating upsets. In addition, this section will describe special safety features incorporated in data of the unit will include: - Valve to valve operation instruction - Start-up procedures - Normal operation procedure - Normal shutdown procedure - Emergency shutdown procedure - Drawings of all equipment such as tables, rolls etc. - Operation and maintenance manuals including start-up and shut-down procedures as follow: - Instruction for periodic maintenance - Instruction and manuals for emergency shut-down - Instruction for operation in Energy shortage (Water, electricity and …) - Instruction for details maintenance and replacing of equipments ( including all special tools , details maintenance procedures, personnel and their experiences, …) - Instruction for periodic inspection for maintenance - Maintenance Planning and Scheduling:

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- Maintenance Planning and Scheduling for operations coordination and maintenance - For Additional Planning and Scheduling for planners and supervisors - Shut down before Capital repairing - Operation after Capital repairing - Start-up procedures - Normal operation procedure - Normal shutdown procedure - Emergency shutdown procedure - Capital repairing procedure - Routine repairing procedure - Preventive Maintenance Essential Care and Condition Monitoring Manual - Safety manuals.

- Description of process:

• A brief description of process flow to provide adequate background to the unit operating personnel.

• Process specification, process flow chart, quality of feed stocks, composition of various materials and required yields and utilities of products, intermediates and by-products. - Process operation conditions:

•

A simplified discussion of cause and effect, of operating variables with consequent

changes in yields, purities, etc.

• Details of operating procedures a. Preliminary operations-preparation and inspection of equipment before start-up. Run in procedure on pumps, compressors, boilers, etc. b. Start-up procedures c. Normal operation d. Normal shut down procedure e. Emergency shutdown procedure. Anticipated emergencies and recommended procedures to result in maximum safety of personnel and equipment. f. Detailed flow charts and process equipment

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g. Water runs procedure control system Employed with details on any special provisions and its bearing on the operations. -

Equipment summary:

Details on equipment by categories and in accordance with the agreed coding system; -

Utility and utility summary:

It will be also specified the list, characteristics and required flow rates of utilities during pitcommissioning and start-up -

Operating records:

The suggested format for proper maintenance and operating records, through: a. Daily log sheet. b. Management reports c. Product test record for quality control at various stages in units. -

Personnel required for operations and maintenance:

Suggested organization for operations and maintenance of plant giving; a. Supervisory staff with duties and responsibilities. b. Operating staff with duties, responsibilities and operating positions. -

Safety of unit and regulation personnel:

Rules and regulations governing the operation area with special precautions to be followed, first aid facilities to be provided shall be discussed. The proper use of special safety equipment shall be described.

17.1.46. Other Required Information a) Any other documents or data which arc reasonable necessary to perform the detailed design procurement and construction, pre-commissioning, commissioning, start-up and operation of the PLANT. b) Estimated manpower requirement with number and qualification for start-up and normal operation of the PROCESS UNITS/UNITS to be submitted. 17.1.47. Effluent Treatment SUPPLIER shall provide basic design inputs/ outputs data and information for treatment of PROCESS UNITS/UNITS effluents with due regard to type, quantity and composition of the effluents and waste disposal (which is to be prepared and included in the respective ENGINEERING DESIGN SPECIFICATION) considering specific requirements of EMPLOYER,

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and as are necessary for design and operation of effluents and waste disposal system with respect to latest version of ISO 14000 & OHSAS 18001 standards.

17.2. Detailed engineering 17.2.1. General SUPPLIER shall prepare/provide all such drawings and documentation which shall be necessary for performing the procurement of EQUIPMENT and materials, construction, precommissioning, commissioning and operation of the PLANT according to chapter 3 (scope of supply). The above drawings and documentation shall include, but not limited to the following: a. Plot plan 1. OVERALL PLOT PLAN of the PLANT

SUPPLIER shall prepare detail layouts and plot plans for PROCESS UNITS/UNITS included in the PLANT. Overall plot plan of the PLANT shall be prepared by SUPPLIER and shall show location of all buildings, battery limits of PROCESS UNITS/UNITS routing of roads and configuration of pipe racks. The plot plant shall be prepared with due consideration to the PROCESS UNITS/UNITS plot plan proposed by SUPPLIER. 2. PROCESS UNITS/UNITS Detailed Plot Plan

Based on overall plot plan of the PLANT, SUPPLIER shall prepare/provide detailed plot plan for PROCESS UNITS/UNITS included in the PLANT. Detailed plot plan shall be on scale and shall show exact location of each equipment with their tag number, interconnections between the equipment, configuration of pipe racks, access ways sewerage and trenches inside the PROCESS UNITS/UNITS, package unit detailed layout (through VENDOR), BATTER LIMIT connections all of the process and utility lines incoming and outgoing and etc. The detailed PROCESS UNITS/UNITS plot plan shall be prepared taking into account easy operation and maintenance of each individual equipment and accessories and parts included in the PROCESS UNITS/UNITS.

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b. Unit Limit Drawings SUPPLIER shall prepare the PROCESS UNITS/UNITS limits drawings showing details of all above and underground interconnections at BATTERY LIMIT (process and utility incoming and outgoing lines) for the PROCESSUNITS/UNITS c. P & I Diagrams These drawings shall show all process equipment and piping, instruments and control systems, for all anticipated operating conditions (start-up, normal operation, shutdown and emergency conditions and etc). Sizes shall be indicated for valves, check valves and number and size for safety valves. The extent of steam and/or electrical tracing and the extent and type of insulation shall be shown. Such details as steam out and purge connections, process equipment vents and lines for alternative operations and start-up / shutdown shall be shown (important elevations for process equipment and lines shall be given). Utilities shall be shown entering and leaving the PROCESS UNITS/UNITS including distribution of each utility to all utility users and/or producers together with utility control systems specific to that user and/or producer. Definitions of piping and instrumentation symbols used shall be provided on a cover sheet for PROCESS UNITS/UNITS P & I Diagrams. Piping and instrumentation diagram shall include: 1.

All process equipment including installed stand-by equipment. (when warehouse standby is available, a note shall be laid down for that specific equipment).

2.

Line size and line identification for all lines.

3.

Insulation requirements of lines (heat conservation, personnel protection, process stabilization).

4.

Tower and vertical drum tangent line elevations.

5.

Horizontal drum minimum elevations and slope.

6.

Relative elevations of all equipment and piping where gravity or 2-phase flow is taking place e.g. re-boilers, condensers, seal pots.

7.

Equipment characteristic parameters or dimensions plus design temperature and pressure and material of construction.

8.

Equipment title and number.

9.

All nozzles on columns, vessels, heat exchangers and tanks and all trays in columns and all internals in vessels shall be shown.

10. Required line slope, relative location of equipment or special conditions such as required vertical 1oop dimensions, gravity lines with or without pockets, etc. 11. Vents and drains required for process or operating reasons (not hydraulic testing). 12. Steam, hot water or solvent tracing of lines and instruments. 13. Gas or liquid purging or flushing of control valves, instruments or relief valves. 14. All start-up, by-pass, shutdown and emergency lines. 15. All instruments required for proper operation of PROCESS UNIT/UNIT. 67

16. Instrumentation control loops including interlocks, sequence and emergency shutdown. 17. Control valves response on air failure. 18. Instrument tag numbers. 19. All details shall be consistent with lie appropriate process flow diagram and other process documents. 20. Process specific installation position of piping components. 21. Kind and item number of special components. 22. Battery Limits and limits of PROCESS UNITS/UNITS. 23. Measuring and control signals transmission. 24. Flow direction of signals when combining several measuring and control circuits. 25. Electrical consumers other than motors, such as heating systems. 26. Kind of signal for specific representation of signalling lines, such as pneumatic electric, hydraulic, function line, capillary tubing. 27. Principal separable connections. 28. Start-up, normal and emergency shutdown, catalyst regeneration, catalyst/chemical/resin loading, unloading and emergency provisions which shall be necessary for safe operation of the PLANT. 29. Alternative operations (all expected modes of operations) which shall be necessary for continuous operation of a PROCESS UNITS/UNITS/PLANT, when other PROCESS UNITS are having shutdown. 30. Sample points and details of sampling. 31. Details of pumps flushing, cooling water, drains, vents, etc.

17.2.2. Equipment a. Engineering drawings and/or specifications and/or data sheets for each individual equipment, materials, etc. b.

Equipment drawings and/or specifications and/or data sheets for towers, reactors, drums, heat exchangers (all types), heaters, tanks and non-code vessels and machinery such as compressors, pumps, turbines and etc, containing sufficient information to enable equipment manufacturers to prepare detailed drawings for manufacturing of equipment.

c.

Equipment arrangement drawings.

d. Detailed drawings and documents of equipment required for proper erection, precommissioning, commissioning, operation and maintenance. e. Materials requisitions containing all required process and engineering information and data and all necessary standard drawings and specifications to permit the purchase of equipment. Material requisitions shall be up to date with all relevant and required information and data to enable any qualified vendor to prepare and submit a proper quotation before final issuance for inviting bids.

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f.

Stress analysis due to piping on equipment considering temperature, pressure and all other expected loads.

g. Calculation sheets of vessel design (through manufacturer) and calculation of thermal stress of piping, structural design and so on. h. Equipment "Sketches and data sheet" for towers, reactors, drums, heat exchangers (all type), tanks and non-coded vessels and machinery such as compressors, pumps, turbines and etc. Such drawings shall contain sufficient information and data to enable equipment manufacturers to prepare shop fabrication drawings. i.

Detail procedure for preservation of equipment during short time and long-time of nonoperation.

j.

Equipment List, containing at least the following information: 1. Item number (tag number) 2. Item descriptions including duty, design and normal conditions 3. Overall dimensions of equipment 4. Erection weight of equipment 5. Type of equipment (e.g. centrifugal or reciprocating pump; Tubular or Air Fin Exchanger etc.) and material of construction. 6. Tangent to tangent length (for Vessels) 7. Absorption and rate of power consumption (steam or electric) 8. Type(s) of Driver(s)

k.

Performance curves for pumps and compressors.

l.

Project engineering specifications for each individual equipment and/or components including but not limited to piping material and drawings, electrical, instrumentation, insulation and painting specifications incorporating of all requirements of EMPLOYER’s and SUPPLIER’S standard drawings and specifications.

17.2.3. Civil work, Structural work and Buildings work a. SITE preparation activities 1. Preparation of general SITE grading drawing shall be done by EMPLOYER. Any engineering required to remove the existing facilities from the SITE as necessary to build the PLANT are included in EMPLOYER Scope. EMPLOYER will specify the interfacing and tie in as required. 2. SUPPLIER shall Design and prepare construction drawings, specifications including procedures for foundations of storage tanks. 3. SUPPLIER shall Design and prepare construction drawings, specifications including procedures for field welding of structures, construction of pipe racks, culverts, retaining walls and dykes (around the storage tanks). 4. SUPPLIER shall Design and prepare road layouts and all other necessary drawings, specifications including procedure to build all roads within the PLANT.

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b. Sewers, Drains and Underground lines and piping. 1. Preparation of schematic sewer layouts. 2. Preparation of sewer flow rate 3. Preparation of Diagram of detailed underground layout drawings, specifications including procedures required for construction. It shall show all sewers, manholes, catch basins, cable trenches, electric cable road crossings and underground normal and pressure piping etc. within the PLANT.

c. Foundations, Concrete Structures and Paving 1. Supplier shall perform site investigation and soil test report according to approved extent of site investigation. 2. SUPPLIER shall were Soil Improvement Schemes and drawings. 3. SUPPLIER shall establish loading data for foundation and equipment supporting structure. 4. Piling specification design, drawings and construction procedures wherever required within the PLANT shall be performed by SUPPLIER. 5. All required Drawings for foundations of all equipment and machinery, structures, pipe racks, buildings compressor shelters and etc, and all foundation drawings specifications and procedures required for proper and efficient construction shall be prepared by SUPPLIER. 6. Loading data and calculation of foundation designs to be specified and submitted to EMPLOYER. 7. SUPPLIER shall prepare Construction drawings specifications and procedures to build all reinforced concrete structures. Where supply of equipment requires the provision of items of civil engineering nature e.g. concrete sumps, SUPPLIER, shall undertake the design in accordance with vendor requirements. 8. Preparation of anchor bolt detail schedules, and specification. 9. Construction drawings, specifications and procedures for all other civil works e.g. paving, graveling roads, culverts and trenches. 10. Bills of quantities and specifications of materials for civil works (e.g. reinforcing bars, cements, anchor bolts etc.) 11. Bar bending schedules. 12. All detailed drawings, specifications and procedures required to perform all civil works of the PLANT.

d. Industrial Buildings SUPPLIER shall prepare and submit at least the following documents/drawings for construction of all the industrial buildings.

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1. Building sketches, layouts and design drawings, specifications and procedures for construction of buildings. 2. Project engineering Specifications for construction of buildings. 3. Detailed architectural, mechanical and electrical drawings, required for construction of the buildings. 4. Plan drawings for buildings, indicating skeleton with major dimensions. 5. Design structural, mechanical and electrical calculations for all buildings. 6. Bills of quantities and specifications for all required materials for construction of buildings. 7. Requirements of the buildings for air conditioning. 8. Requirements of the buildings for fire-fighting and fire protection. 9. Requirements of the buildings for fire alarm system.

e. Structures SUPPLIER shall prepare and submit at least following documents/drawings on structures work.

1. Complete arrangement drawings for steel structures with main member sizes, plan and framing elevation typical sections, and details for preparation of shop detailed drawings and fabrication work.

2. Loading diagrams and calculation results for all structures. 3. Steel structure drawings for equipment supports, racks, platforms, ladders and stairways, etc with sufficient details required for preparation of shop detailed drawings and fabrication Work.

4. Steel structure project engineering specifications and standard details for hand rails, equipment supports, racks, stairs, ladders, platforms, fire proofing, etc.

5. Material requisition for steel structures. 6. Developing and designing special members of structural steel which may become necessary for handling or supporting of special equipment and items during manufacturing, transportation and construction of the PLANT.

7. Preparation of all required specification including procedures standard and specification for manufacturing and construction of structures.

8. Preparation of shop fabrication drawings. 9. Preparation of welding procedures, welding qualifications and inspection certificates for main members of steel structures.

f. Fire Proofing SUPPLIER shall prepare and submit at least following documents/drawings on fire proofing: • Fire proofing requirements for steel structures, vessels, columns, reactors and etc. skirts, supports, etc. and same shall be shown on appropriate drawings.

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• Fire proofing project engineering specifications and standard drawings. • Fire proofing material specifications and bills of quantities.

17.2.4. Design calculation for major equipment, duct work.

17.2.5. Piping SUPPLIER shall prepare at least the following documents/drawings for piping: 1. Piping design, flexibility, fabrication, erection, testing, flushing and other required specification. 2. Piping materials classification and specifications for PROCESS and various services in the PLANT as per technical specifications, (codes & standards) and (design criteria) of T.S. of this CONTRASCT here to and SUPPLIER's requirements. Considering corrosion, erosion, high temperature and high pressure, all expected special conditions and etc. 3. Piping arrangement for all pipes on the pipe racks included in the PLANT. 4. Cross-sectional drawings of all piping entering and leaving PROCESS UNITS/UNITS BATTERY LIMIT. 5. Layout drawings and Sections. 6. Isometric drawings, (except for long runs shown on plan drawings) of all piping systems, indicating all fittings and materials and referring to sand blasting, prefabrication

(*)

,

fabrication, erection, surface preparation, painting and insulation in accordance with the specifications and procedures. Test pressure and its media shall also be specified. 7. Piping arrangement drawings for all underground piping included in the PLANT. 8. Detail drawings and specifications for underground piping and its protection device. 9. Detail piping arrangement drawings and / or isometrics for process, utility, instrument air and all other various services and steam/electric tracing in the PLANT. These shall cover requirements for prefabrication (*), fabrication, erection, pre-commissioning, commissioning, operation and maintenance in accordance with the Approved for Construction P & ID’s. 10. Detail drawings or catalogue drawings and specifications of valves fittings, traps, safety valves, control valves and all other piping components included in the PLANT. 11. Piping drawings for match lines (interconnections) at BATTERY LIMIT. 12. Detail piping drawings, including piping standard drawings including details required, for vent and drains required for process and operating reasons in the PLANT including hydraulic testing and instrument installation drawing. 13. Piping standard drawing indicating the typical detail of required support, anchors and guides, for all piping thin the PLANT.

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14. Piping Drawings indicating Location of required supports, anchors and guides, for all piping within the PLANT. 15. Steam tracing detail drawings and specifications. Such drawings shall contain all information

(*)

, data and procedures required for construction/erection, operation and

maintenance. 16. Flexibility specification and calculations and stress analysis results for all piping systems as set out under Project Specifications including piping supports, especially for those systems subject to high temperature/pressure and other loadings. (*)

Excluding spool drawings required for field fabrication.

17. Vessel trims and special support design. 18. Colour coding of painting for piping suitable from safety and operation point of view. 19. Initial, intermediate and final material take-off for all piping materials, components and items included in the PLANT. These take-offs shall cover all required piping materials, components and items of the PLANT, otherwise supplementary take-offs shall he performed up to complete fulfilment of the requirements. 20. Line lists showing complete line identification (line size, service, Unit No, P& ID No, pipe class, operating and design temperatures and pressures, type of insulation and etc.), line extremities, maximum pressure, maximum temperature, material flowing and it’s condition (vapour, liquid, mixture), quantity, velocity, pressure drop per unit length density and etc. 21. Pressure test diagrams and hydrostatic test P & ID shall be issued by SUPPLIER. 22. All design calculations result, information and data in respect of preliminary hydraulic design of the piping system and final or adjusted hydraulic design calculations, data, information and configurations of the PLANT.

17.2.6. GA drawings for piping and duct work including support drawings. 17.2.7. Hydraulic system calculations, GA/layout drawings, specifications of equipment, pipes, valves and fittings, hydraulic fluids, etc. Insulation, drawings/specifications in category wise.

17.2.8. Insulation SUPPLIER shall prepare the following detailed documents as minimum requirements on insulations. Insulation specification and schedule for each vessel, tower, drum, heat exchanger, pipelines and so on indicating operating and design temperatures, type of insulation, service, thickness of insulation and insulation specifications including type and number of tracers all required

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drawings and procedures for construction/erection of insulation and all other related material to be provided. Wrapping requirements and specifications shall be provided in detail. Initial and final material take-off and requisitions, for pipe lines and equipment insulation material including wrapping and all other required material for insulation. Design calculations result in respect of insulation of piping and equipment.

17.2.9. GA drawings for underground and over ground services and utilities (including water system). Vendor drawings for bought out items: I.2.10.) VENDOR drawings and documents SUPPLIER shall provide at least the following VENDOR documents: 1. Certified VENDOR drawings for all equipment to be approved by SUPPLIER and certified by VENDOR. VENDOR drawings shall include foundation loading plans, general arrangement and detail drawings. 2. Construction Installation and operation instructions to be issued at least eight weeks prior to shipping of respective items, equipment, etc. 3. Equipment dossier for rotary, fixed and package equipment, including design calculations, welding procedures, welding qualifications, material test certificates, inspection certificates, etc. 4. Recommended spare parts list for pre-commissioning, commissioning and 2 years operation. 5. Performance test certificates for all rotating equipment (as per Annex inspection procedure) for tests carried out at the manufacturer's shop. All inspection reports with necessary and sufficient information for all of the Equipment, Machinery and Materials to be submitted to EMPLOYER on due time to be reviewed and commented or APPROVED (wherever applicable) by EMPLOYER. The mentioned documents shall be categorized as Equipment Quality Control and Testing Manual (EQCTM) and should be approved by the EMPLOYER to release the inspection certificate (IC) according to the stipulations of item 20.1.5.K of Appendix 20. 6. Special measures to protect the bearings, shafts, gears and other parts of rotating machines during transportation, storage at SITE and against emergency (partial or total) shutdowns of the PLANT, or as a result of a cut-off of steam or electric power, due to lack of oil or cooling water 7. Electrical and instrument diagrams, wherever applicable.

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17.2.11. Drawings and data of utilities, fire fighting, lighting, earthing, air conditioning and ventilation, drainage, etc. 17.2.12. Engineering specification for fabrication, inspection and installation of equipment. 17.2.13. Refractory lining work drawings and refractory course drawings. 17.2.14. List of bought out items with specifications. 17.2.15. Instruction manuals for Erection Heating-up/commissioning. 17.2.16. Consolidated list of foundation bolts. 17.2.17. Painting SUPPLIER shall prepare the following documents as minimum requirements on painting:

1. Painting schedule with references to the applicable painting specifications and codes.

2. Initial material take-offs. 3. Methods and procedures of surface preparation in detail. 4. Methods and procedures of painting of EQUIPMENT and Material in the manufacturer workshop and at SITE in detail.

17.2.18. GA drawings for structural work along with design calculations. 17.2.19. Safety manuals. 17.2.20. Quality assurance plan for all equipment. 17.2.21. Predicted performance curve of pump sets and actual performance curves. 17.2.22. Detailed specifications of pumps with material of construction and motor lists. 17.2.23. Detailed specifications of cooling towers, fan and motor details and final heat load calculations. 17.2.24. Layout of water treatment plant including pump houses, cooling towers, make up water treatment plant, scale pits, filtration area, clarifiers, thickener, etc. and piping incorporating final equipment & piping sizes, as well as other auxiliary units and facilities. 17.2.25. Instrumentation

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SUPPLIER shall prepare, but not limited to, the following drawings and documents: 1.

Instrument index containing tag no’s, service, process conditions, type, size, range, alarm / trip set points, manufacturer, model no, P & ID no, reference to other documents etc.

2.

Systems architecture (hardware configurations) drawings.

3.

General specifications for instruments, control system and accessories in respect of engineering, procurement, manufacturing, inspection construction and operation (One document for instrumentation overall practice and individual documents for further attachment to material requisitions), plus specification for package instruments, instrument cables, instrument air calculation, F&G specification and instruments installation.

4.

Sizing calculations.

5.

Instrument data sheets (for further attachment to material requisitions).

6.

Cause and effect diagrams.

7.

Interlock

and

sequence

(ESD

and

non

ESD)

description

and

logic

diagram/flowcharts according to IEC-61131.3. 7.1. Risk Analysis Documents for ESD. 8.

Alarm/trip set points.

9.

Loop sketches.

10. Instrument Loop diagrams (ILD) and Instrument Segment Diagram. 11. Instrument hook-up drawings with material requirements. 12. Instrument mounting drawings with material requirements. 13. Instrument heat tracing drawings with material requirements. 14. Instrument Cable tray/Ladder/Trench layout. 15. Instrument location drawings (layouts) showing positions of instruments, junction boxes, local panels, cable routing, instrument air header take off valves and cables on trays/ladders and/or in trenches. 16. Control / auxiliary / analyzers room layout, showing all necessary details including locations, cable entry and route, tray / trench details etc. 17. Front view drawings of control panels / consoles with dimensions. 18. Instrument Earthing Details. 19. Data required for instruments / systems configuration such as I/O summary, Host connection, diagrams, flow charts, mathematics, graphics, layouts, grouping lists, ranges, scales, parameters, set points, colour codes etc. 20. Instrument cable lists and schedules. 21. Material take off (MTO) lists. 22. Material requisitions, bid evaluations and purchase orders for instruments / systems and bulk materials. 23. Instrument JB diagram/connection.

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24. Vendor's technical drawings, catalogues and documents including installation, operation, calibration, configuration, programming and maintenance manuals for instruments/systems with illustrated parts lists. 25. Instruments / systems configuration documents including device description / capability files, software details, source and application programs etc. 26. Panels/consoles / cabinets internal layout. 27. Panels / consoles / cabinets interconnection block diagram with cable nos. 28. Power supply distribution drawings. 29. Interposing diagrams / philosophy between control systems and MCC. 30. Termination and wiring diagrams as well as hardware configuration for construction and troubleshooting purposes. 31. Spare parts lists. 32. Tests, inspections and QC certificates and reports. 33. Power consumption for instrument UPS. Connection between Aux. And HMI interface

17.2.26. Electrical SUPPLIER shall prepare/provide, but not limited to the following documents for electrical works: 1. Area classification drawings 2. Schematic one-Line diagrams of power wiring and instrument power supply. 3. Load summary and analysis. 4. System design including voltage profile, reacceleration. 5. Relay setting schedule. 6. Grounding system layout. 7. Emergency supply including uninterrupted power supply system design and specifications. 8. Battery charger specifications and storage battery capacity requirements. 9. Schematic wiring diagrams for all circuit breakers and electrical items having internal wiring or relays. 10. Cable schedules and routing showing the service, type, size, length and number of cores. 11. Complete list of starters with sufficient capacity and specifications for each. 12. Complete list of switchgear with sufficient capacity and specifications for each and all categories. 13. Layout of switchgear rooms. 14. All lighting, earthing, control station and other miscellaneous equipment fixing and mounting details including specifications.

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15. Initial and final material take-offs for all electrical equipment, accessories and materials. 16. Material requisitions for all electrical accessories, equipment and materials including heat tracing material, if any. 17. Design, drawings and specifications for materials required for electric heat tracing (if any). 18. Detail drawings and documents of transformers required for erection, operation and maintenance. 19. Complete one line diagram covering all circuits from incoming lines to major equipment indicating metering, relaying and main interlocking systems. 20. Specifications of all electrical equipment and all electrical component and accessories showing connection diagram, external view with physical dimensions, specifications of apparatuses and accessories and instruction manual in sufficient detail. 21. Motor schedule showing: Service, number (normal operation and stand by) number of poles, output capacity, type, classification and remarks indicating any special requirement. 22. Impedance map and calculations results of fault current on every feeder bus bar. 23. Calculation analysis and results sheets and start-up detail (taking into account power consumption and requirements for start-up of motors) for large capacity motors, line failure, instant load transferring in case of important line failure and so on. 24. Protection co-ordination curves in the whole electrical system, including protection in main substation. 25. Block diagrams, connection diagrams, design philosophy and instruction manuals for interlocking systems, alarm system and other complicated power and control systems. 26. Plot plan showing the location of major equipment, battery charger room and classification of hazardous locations. 27. Physical location of lighting fixtures, receptacles and wiring as well as their installation details, as per area classification. 28. Physical location of electrical equipment and wiring installed and installation details. 29. Physical location of grounding electrodes, equipment to be grounded and wiring layouts as well as their installation details. 30. Engineering, manufacturing, inspection requirements, construction / erection, precommissioning and commissioning specification and procedures for all electrical Components, equipment, accessories and materials. 31. Symbols 32. Cable cutting schedule

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33. Cable orientation on trays and/or trenches. 34. Cable room tray orientation 35. PDCS system installation. 36. PDCS I/O list (include serial links) 37. Logic sequence diagram for PDCS system 38. PDCS software details. 39. Operation and maintenance manual for PDCS, complete with illustrated Spares list. 40. Material take off (MTO) lists. 41. Cable lists and schedules.

17.2.27. Miscellaneous Equipment and Materials 1. Specifications for design and fabrication, for other EQUIPMENT and Materials, electric motors, valves and all package units. These shall also include catalyst, adsorbent, resin, chemicals and solid handling, loading and unloading equipment and accessories, chemical feed system fillers and etc. 2. Specifications and procedures for construction/erection, pre-commissioning, commissioning and operation (all expected modes) for all of the EQUIPMENT. Machinery and Materials named and specified in item 1 above in detail. 3. Data sheets including all required information and data for all the EQUIPMENT. Machinery and Materials named and specified in item 1 above in detail. 4. Standard drawings for all of the EQUIPMENT, Machinery and Materials named and specified in item 1 above in detail (if applicable). 5. Any other drawings which are necessary to prepare shop fabrication by manufacturer and assembly drawings for all of the EQUIPMENT Machinery and Materials named and specified in item 1 above in detail.

17.3. For Information/comments/review 1.

Performance data, characteristic curves including duty points.

2.

Drawings for approval of statutory authorities.

3.

Instructions for storage and re-conservation including those for electrical, instrumentation and communication items.

4.

Operation, safety and maintenance manuals.

5.

Manufacturing drawings for spares (including those for proprietary items) and ordering specifications for spares including spare lists.

6.

Drawings for various sizes & shapes of refractory bricks.

7.

Copies of referred standards/codes.

8.

Laboratory manuals.

79

9.

Piping isometric drawings.

10. List of spares and consumables. 11. Fabrication drawings for structural steel work.

17.4. Final documents to be submitted

1.

As-built drawings

2.

Test/inspection certificates for all equipment in bound volume.

3.

Report on heating-up, commissioning and performance guarantee (PG) tests with all recorded figures.

4.

Compiled report on PAC & FAC.

5.

Operation, maintenance and safety manuals.

6.

List of spares including ordering specifications, manufacturing drawings including shop drawings, bill of material for all spares.

7.

Ordering specifications for operating consumables & supplies.

8.

Consolidated list of all drawings and documents for the project.

9.

Integrated bill of material data bank for whole steel plant complex, auxiliary plants, units and facilities.

17.5. Electrics, automation and instrumentation Refer to related chapter for details of drawings and documents to be submitted for electrics, automation, instrumentation and, communication systems.

17.6. Technical documentation delivered by Supplier to Employer 17.6.1. General Description Overall Responsibility of the Supplier: The Supplier shall undertake the overall responsibility for the contract plant within the battery limits in terms of the technical reliability and completeness, according to the technical responsibility as stipulated in the technical Appendixes and ensure the contract plant will achieve the technical performance and guarantee figures as specified in the Appendixes. The Supplier shall be responsible for the overall design of the plant as well as the completeness and the correctness of their design. The scope of design to be done by Supplier and Employer is detailed in the technical Appendixes.

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The Supplier shall be obligated to supply the Employer with all technical documentation including drawings for design, assembling, erection, commissioning, normal operation and maintenance of the plant as far as it belongs to Suppliers scope of supply. The scope of the technical documentation and their delivery schedule is detailed in this Appendix. Documents formulary and numbers of copies to be submitted: Drawings are to be carried out based on AutoCAD 2005 software. The drawings and documents will be transmitted by e-mail or courier service. Number of copies to be submitted is 6 copies and 2 set of CD. 17.6.2. Scope for the documentation Basic Information supplied by Supplier during kickoff meeting: The kick-off meeting will be held two weeks after Contract effectiveness. 17.6.3. Scope of basic engineering services The basic engineering will be related to the project and process and be of sufficient technical explanation to enable the Employer to generate the required detail engineering. The following engineering documentation will be delivered according to the scope division list. Submitting Date (after

Effectiveness

date

of

contract): -

Basic flow diagram

6 weeks

-

Process function description

-

Process layout

6 weeks

-

Mechanical equipment

6 weeks

-

P&I diagram

6 weeks

-

Single line diagram

6 weeks

-

Motor and component list

6 weeks

-

Automation Hardware configuration

-

Installation requirements for electric equipment

6 weeks

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-

-

Requirements for control room layout arrangement Requirements

for

electrical

room

layout

arrangement

6 weeks

6 weeks

17.6.4. Scope of detail engineering services The detail engineering will be carried out according to the scope of supplies. Submitting Date (after kick-off meeting):

-

Overall layout

14 weeks

-

Mechanical equipment and field electrical device

14 weeks

Piping list 16 weeks

Isometric drawing for piping Automation and Instrumentation Layout PLC or DCS I/O list

-

Instrument list

-

Instrument Hook up diagram

-

Specification for process control system

16 weeks

-

Operation manual (preliminary)

24 weeks

-

Supplier

detail

16 weeks

design

drawings

for

equipment,

manufactured by Employer as per this section.

16 weeks

-

Equipment load of Supplier supply

10 weeks

-

Assembly details of Supplier supply

24 weeks

PLC logic (software and document) HMI and network (software and document)

-

Function description (logical diagram) for programming

20 Weeks

(unloading system, silo and dispenser, value control

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procedure and logic interlock) Principal arrangement of cabinets incl. circuit diagram,

-

terminal diagram, and cable list Diagram of power supply and distribution

-

All catalogues of electrical and mechanical equipment as

-

far as supplier is concerned and as far as available

18 weeks

18 weeks

36 weeks

The basic engineering will be approved jointly during the

-

basic technical meeting. Erection manual

-

36 weeks

Operation manual and maintenance manual will be

-

submitted in 2 copies, each in English language and will be submitted in two stages: Preliminary operation manual will be submitted four weeks before plant commissioning. Final operation manual will be submitted about one month after commissioning. Bill of Material for mechanical , electrical and automation and communication and other parts

18. PERFORMANCE GUARANTEES AND TEST POCEDURES

18.1 Description The Supplier should provide equipment with the up-to-date technology, reliable and of best quality incorporating/Integration with existing CCM equipment and mill plant. There would be 3 stages for the test: Cold Commissioning, Hot Commissioning and Acceptance Test.

-

Cold Commissioning means individual and area cold test; Hot Commissioning means load test with hot material; Acceptance Test means performance test.

During the period of Commissioning and Performance Test, the Supplier should give instructions and supervision, general plan and commissioning schedule. The Supplier will also take the responsibility on technical analysis of some problems occurred. The Employer will be responsible for organization and application of the whole work under the instructions and supervisions of the Supplier.

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Any and all supplies and works relating to the Project to be executed by the Employer, such as civil, building, erection and commissioning works, shall be properly provided or performed by the Employer in accordance with the requirements of the Contract and/or the approved manuals, drawings and other relevant technical documents as far as furnished by the Supplier under the Contract, and/or the approved instructions and supervision given by the Supplier’s Personnel. The Employer shall, during the tests (including any repeated run thereof), provide, at own expense, skilled and well-trained labours and operators, raw materials and utilities in sufficient quantity with required quality, needed for proper execution of the tests, in accordance with the requirements, the manuals, drawings and other relevant technical documents furnished by the Supplier, the instructions and supervision given by the Supplier’s Personnel, and shall give the Supplier’s Personnel opportunities to check them in advance or at all times during the tests. The Tests will be performed by Employer’s personnel under the supervision of Supplier’s supervisory personnel. Employer’s personnel shall follow the instructions of Supplier’s personnel.

18.2 Cold Commissioning After the completion of assembly and erection of the equipment, the Employer shall carry out the individual and area no-load tests under the instructions and supervision given by the Supplier’s Personnel. The equipment supplied by Employer will be tested in the same manner as the equipment supplied by Supplier, however, is under the responsibility of the Employer as long as Supplier’s Basic Design is correct. The respective No-Load Test consisting of sequenced series of individual equipment tests will be carried out to verify the: •

Completeness

•

Proper assembly

•

Compliance with the Contract Specification

•

Function under no-load conditions

•

Readiness for the equipment for the hot commissioning phase.

During the period of No-Load Test, both the Supplier and the Employer shall take the records for individual equipment performances, defaults and repair states, as well as general valuation on the rolling mill and signed by both parties. Individual No-Load Test Upon completion of erection and installation of each unit of the equipment supplied by Supplier, including connection thereof to all necessary electric power supply and utilities, each unit is subject to individual No-Load Tests to be carried out without production load or charge. The Supplier shall check and inspect the readiness for such individual No-Load Tests. Immediately after the Supplier has confirmed and been satisfied with the readiness for such individual No-Load Tests through the aforesaid check and inspection, the Supplier shall notify the Employer to that effect. Upon receipt of the aforesaid Supplier’s notice, the Employer shall carry out the individual No-Load Tests in accordance with the provisions of the Contract and under the instructions and supervision given by the Supplier’s Personnel, in order to confirm that the unit of the equipment concerned meets the mechanical functional requirements specified in the Technical Specification. The detailed procedures, programs, methods and conditions of the individual No-Load Test shall be defined by the Supplier and the Employer through mutual consultation in due

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course before the individual No-Load Tests. However the procedures, programs, methods and conditions of the individual No-Load Test must confirm by Employer. During the period of the Individual No-Load Test the Employer as well as the Supplier shall be responsible for the recording and checking of all relevant operating data, test parameters as well as all tests results. Area Cold Test Upon successful completion of all the individual No-Load Tests for all of the area equipment, the Employer shall carry out the Area Cold Test under the instruction and supervision of Supplier’s personnel.

18.3 Hot commissioning with Load Tests After successful completion of No-Load Tests, the Employer shall carry out the hot commissioning under the instructions and supervision given by the Supplier’s Personnel. The hot commissioning including load tests shall be carried out by the Employer in accordance with the technical documents supplied by the Supplier and the instructions and supervision given by the Supplier’s Personnel. During the period of hot commissioning including load tests, the Supplier and Employer shall jointly take records of detailed performance, defaults, corrections and matching condition of individual equipment. Both the Supplier and Employer shall agree about the general valuation on readiness for the performance tests. The detailed procedures, programs, methods and conditions of the hot commissioning including load tests shall be defined by the Supplier and the Employer through mutual consultation in due course of hot commissioning. However the procedures, programs, methods and conditions of the hot commissioning including load Test must confirm by Employer Test Items for the Hot Commissioning During the hot commissioning including load test it shall be verified, that: •

Each equipment works smoothly during hot commissioning.

•

Equipment conforms to the functions specified in the technical specifications

•

The equipment is ready for Performance Test.

18.4 General Terms for Performance Tests Final Acceptance Certificate (FAC) As soon as reasonably possible after commencement of hot commissioning the performance test of each unit supplied by Supplier shall be carried out in order to confirm the performance guarantee values. The date(s) and program(s) for the performance test shall be mutually agreed between Employer’s and Supplier’s authorized representatives. Prior to commencement of the performance test, the Supplier will submit to Employer a “Notice of readiness for performance test”.

85

The Performance Test will be carried out to prove that: •

The equipment accuracy is in accordance with the guarantee values.

•

The changing times between hot and cold charging are in accordance with the guarantee values.

Time Schedule of Performance Test The performance test shall be performed within the time as specified in the project time schedule. Performance Test Procedure The Supplier will prepare a detailed performance test procedure. The performance test will be performed by Employer’s personnel in close co-operation with the supervisory personnel of the Supplier. Employer’s personnel shall follow the instructions of Supplier’s personnel. The test results shall be recorded by the Employer and the Supplier. The performance testreport of each single test shall be prepared by the Supplier. For each performance test the test time will be five (5) net hours continuously. Delays not attributable to Supplier as well as the times of interruptions due to lack of performance of Employer´s personnel and obligations will not be considered as downtime. The Employer shall fulfill all its preconditions for performing the tests. Upon successful completion of each performance test a protocol will be signed by both parties within three (3) days and after completion of all performance tests the Employer shall issue the Final Acceptance Certificate within three (3) days. The issuing of the individual test protocols and/or the FAC shall not be withheld by the Employer for minor faults or deviations. Such faults and/or deviations, if any, for which the Supplier is responsible but, which do not impair the performance of the related equipment shall be stated in a protocol with exact dates for their rectification by the Supplier. If the performance test is not completed successfully for reasons attributable to the Supplier, the deficiency will be corrected by the Supplier and the test will be repeated in respect to the performance guarantee value not being achieved. If either of the performance guarantee values have not been achieved for reasons attributable to the Supplier even after repetitions, the provisions of the commercial Contract shall apply. Supplier has the right to execute the performance tests with its own operating and maintenance personnel with the assistance of Employer's personnel if required by the Supplier. In case the performance tests have to be repeated for reasons not attributable to the Supplier, the Employer will bear all costs for such retesting including the costs for Supplier's supervision personnel. If the performance test cannot be completed successfully for reasons not attributable to the Supplier, the final acceptance shall be deemed occurred at the expiration of 3 months calculated from the initially scheduled date of final acceptance and the final acceptance certificate shall be issued. With the final acceptance certificate the equipment is considered as accepted by the Employer, and the Supplier shall be released from his contractual obligations in respect of the performance guarantees.

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19.

Technical Appendices

Appendix A – Company Information Company Name Address Web:

Esfahan Steel Company (ESCo) Zobahan Highway, Esfahan, Iran http://www.esfahansteel.com

Contact 1: Tel: Fax: Email:

Mr Khazaei, (Energy Management Department) +98 315 257 5126 +98 315 257 5130 [email protected]

Contact 2: Tel: Fax: Email:

Mr Nourmohammadi, (Plan & Development Department) +98 315 257 4511 +98 315 257 5038 [email protected]

Contact 3: Tel: Fax: Email:

Mr kheirati, (Contract Department) +98 315 257 2228 +98 315 257 3717 [email protected]

A.1 Summary of Esfahan Steel Company ESCo is the largest manufacturer of constructional steel products in Iran with a production capacity of 2.5 million tonnes steel per year. Production started in 1971 at its fully integrated steelworks located outside Esfahan. Demand for steel in Iran is increasing and ESCo plans to increase production to 5 million tonnes by 2015. ESCo is a significant consumer of energy and natural resources. In 2011, ESCo consumed around 36 million gigajoules (GJ) of natural gas and over 600,000 tonnes of coking coal. In terms of efficiency, ESCo consumed 2.1 GJ of fuel (including 1.7 GJ of imported natural gas) for each tonne of steel rolled at Rolling Mill 500 in 2012. Comparing the efficiency of ESCo to examples of international best practice, which range from 0.87 to 1.35 GJ/t with hot charging, indicates that significant improvements and energy savings are possible. A.2 Overview of production ESCo is a fully integrated steel works with a production capacity of 2.5 million tonnes steel per year. ESCo produced 2,374,627 tonnes of crude steel and 2,822,821tonnes of finished steel in 2011. ESCo plans to increase production capacity to 3.6 million tonnes in 2014 and 5 million tonnes in 2015. Operation is continuous with three working shifts. The overall process is shown in Figure 4 and described below. •

Metallurgical coke is produced on site from imported coking coal in one of three coke ovens. Part of the coke oven gas is recovered and utilised in the power plant and elsewhere onsite.

•

Sinter is also produced onsite.

•

Three blast furnaces produce pig iron. Hot metal is transported using torpedo ladles by rail.

87

•

One vertical shaft furnace (based on the MIDREX design) produces direct reduced iron (DRI) which is cold charged to the blast furnaces. Vertical shaft gas is recovered and is utilised on site including the firing of the rolling mill heating furnaces.

•

3 basic oxygen furnaces (BOFs or converters) provided by Nippon produce liquid steel.

•

Liquid steel is cast into billets using four curve-type continuous casting machines (CCM). A new continuous caster (CCM No.5) is under construction (supplied by DANIELI).

•

Four rolling mills (Rolling Mills 300, 350, 500 and 650) produce various types of constructional steel products. Wire rods are also manufactured onsite.

•

Onsite power plants generate the electricity required by the iron and steel making processes.

Figure 4 Diagram of the iron and steel making process at ESCo.

The production process is controlled manually using traditional management and communication techniques between departments. Production output is scheduled and coordinated between production departments on a daily, weekly and monthly basis. Production quality control reports are also prepared daily, weekly and monthly. A.3 Products ESCo produces various standardised constructional steel products including I-beam (parallel flanged with heights of between 120 and 180mm), equal angles (with widths of between 80 and 120 mm) , channels (C-shape cross section with widths of between 80 and 120 mm) and round bar (plain and deformed rounds bars) as shown in Table 2. Products are manufactured against IPE, DIN and EN standards. The standards and product specifications are detail in Appendix B. Table 2 Constructional steel products produced by ESCo. Product

Image

Drawing

88

I-beam (parallel flanged with heights of between 120 and 180mm)

Equal angles (with widths of between 80 and 120 mm)

Round bar (plain and deformed rounds bars)

Channels (C-shape cross section with widths of between 80 and 120 mm)

A.4 Energy consumption ESCo is a significant consumer of energy and natural resources and emitter of subsequent greenhouse gases (GHG) and air pollutants. In 2011, ESCo consumed around 36 million GJ of natural gas and over 600,000 tonnes of coking coal. The total net energy consumed per tonne of product for ESCo, or specific energy consumption (SEC), is shown in Table. SEC indicates the overall energy efficiency of production. SEC of pig iron, crude steel and rolled steel (2009, 2010 and 2011) has been provided by IFCO. (1) The SEC of Rolling Mill 500 is based on data provided directly by ESCo. This shows that overall energy consumption in 2009 was more efficient than compared to 2011. However, the efficiency of Rolling Mill 500 in 2012 has improved by almost 25% compared to 2011. ESCo consumed 2.1 GJ/t of fuel (including 1.7 GJ/t of imported natural gas) for each tonne of steel rolled at Rolling Mill 500 in 2012. Comparing the efficiency of ESCo to examples of international best practice (which range from 0.87 to 1.35 GJ/t with hot charging) indicates that significant improvements and energy savings are possible.

89

Table3. Specific Energy Consumption (SEC) for pig iron, crude steel and rolled steel in 2009, 2010 and 2011. Parameter

Unit

2009

2010

2011

2012

Pig Iron: Specific Fuel Consumption

GJ/tonne

14.2

15.51

14.76

Specific Electricity Consumption

GJ/tonne

0.36

0.43

0.49

Specific Energy Consumption

GJ/tonne

14.55

15.9

15.26

Specific Fuel Consumption

GJ/tonne

0.11

0.1

-0.14

Specific Electricity Consumption

GJ/tonne

0.57

0.57

0.54

Specific Energy Consumption

GJ/tonne

0.68

0.57

0.39

Specific Fuel Consumption

GJ/tonne

2.88

3.13

3.11

Specific Electricity Consumption

GJ/tonne

0.38

0.39

0.37

Specific Energy Consumption

GJ/tonne

3.26

3.53

3.48

Crude Steel SEC:

Rolled Steel SEC:

Rolling Mill 500 SEC: Specific Fuel Consumption

GJ/tonne

2.86

2.14

Specific Electricity Consumption

GJ/tonne

Specific Energy Consumption

GJ/tonne

2.86

2.14

Specific Gas Consumption

GJ/tonne

2.28

1.69

A.5 Organisation structure and key departments The relevant departments involved in this project are identified in Figure 5. Detailed discussions were held with the managers from each department to gather important information related to the hot charging project, including functional requirements of the hot charging system and potential technical barriers, and to establish what assistance and training would be needed. ESCo’s engineering department provided important data following the site visit. The Procurement department will be an important point of liaison for UNIDO when procuring the hot charging plant.

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Figure 5: Organisation structure showing selected departments involved in this project. Senior Management

Opertation Department

Expansion and Project Pepartment

Procurument Department

Steelmaking

Rolling

Contract Manager

Quality Control

Automation

Energy Procurement

Equipment Procurement

Engineering Department

Energy Management

A.6 Quality control Product quality is controlled using a combination of sampling and chemical analysis of pig iron and liquid steel and visual inspection of billets.

A.6.1 Sampling Samples of liquid steel are taken at number stages in the process. 1. Converter 2. Ladle Furnace 3. Tundish: •

Sample A –at the beginning of each 125 tonne ladle of hot metal poured into the Tundish.

•

Sample M –after 50% of the melt has been poured.

•

Sample B –at the end of each melt.

The samples are sent to the laboratory where the chemical composition is analysed to ensure the correct quality and identify any abnormalities. The time taken to complete sampling and chemical analysis at the Tundish is important as this affects the charging of the rolling mill. Billets cannot be charged to the reheat furnace unless positive results from testing on sample M are obtained. This timing is outlined below. •

Total time for whole melt to be discharged into Tundish –35 minutes.

•

Time to take sample M from start of pour– 17.5minutes.

•

Time taken to transfer sample to lab – 5 minutes.

•

Lab testing – 10 minutes.

Following completion of the CCM No. 5, ESCo plans to mobilise a mobile, online sampling unit to test the chemical composition of liquid steel in real time. Therefore, sampling is not considered to be a limiting factor on hot charging.

A.6.2 Visual inspection After one batch of hot metal is casted, the billets are cut, stamped and transferred from the bearing grid by electromagnetic crane and stacked in the billet stock yard where they are allowed to cool to ambient temperature over a period of about six hours. The visual inspection is conducted by the 91

Quality Control (QC) team on at least six billets from each batch. The billets are examined to identify a range of potential defects as described in Table 3. If a billet fails visual inspection, then billets are reconditioned, using manual techniques such as surface rectification, scarfing or grinding. If the defect is serious and cannot be rectified, then the billet is rejected as scrap. If several serious defects are identified on each billet inspected, then the whole batch may have to be transferred for reconditioning or rejected. Table 3 Visual inspection aims to detect surface, dimension and volume defects. No.

Defect

Acceptance level/ tolerances

Modification

1

Pinholes and blowholes (caused by gas bubbles)

No pinholes and blowholes

Scarfing

2

Cracks in length

≤10% of billet’s width go to be fixed

Scarfing

3

Cracks in width

None

_

4

Slag

_

Scarfing

5

Belt

None

_

6

Bending

≤ 70 (mm)

_

7

Rhombus

Diagonal difference:

Edging off

• • 8

Dimension

9

Rough ends

Remarks

≤ 9mm for 150 x 150 ≤ 15mm for 200 x 200 ≤ ±4% < 12 (mm)

Re-cutting

≤ ±4%

Scarfing

(not cut smooth) 10

Concave or convex volume

A.7 Continuous Casting Machine No.5 ESCo is constructing a new continuous casting line (CCM No.5). The equipment has been supplied by DANIELI and is due to be commissioned at expected in the first half of 2015. The foundations were being laid at the time of the site visit. The new CCM No.5 will produce 1 million tonnes per year of low, medium and high carbon steels and high strength low alloy steels (about 90% low and medium carbon steels in total). The plant includes continuous caster, , billet cooling, conditioning, storage and dispatch section along with all associated services, utilities and systems. A.8 Rolling Mill 500 Rolling Mill 500 (RM500) is a medium section hot rolling mill capable of producing 1 million tonnes of steel per annum (965,685 tonnes were rolled in 2012). The mill produces I-beam, equal angles and channel products and currently operates are 140 tonne per hour. The maximum possible throughput 92

is 200 t/h (although this would require modification). Stoppage time for product change is around 4 hours. The rolling mill receives billets of sizes of 150 x 150mm and 200 x 200mm typically of lengths of between 10 and 12m. Billet weight ranges from 1.85 to 5.68 tonnes (depending on dimension). The primary and secondary roller drives system consists of 14 electric motor driven rollers. The primary and secondary drives and control system was recently replaced with ANSALDO SISTEMI INDUSTRIALI drives and Siemens controls.

A.8.1 Billet Reheat furnace RM500 uses a walking hearth reheat furnace to reheat billets from ambient temperature up to 1250°C before rolling. The original technical description is included in Table 6 in

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Appendix E. The original side-view technical drawing is shown in Appendix F. The furnace consists of six firing zones with 128 burners in total positioned in the ceiling and walls. Current operating capacity is 140 t/h (with maximum capacity is 200 tonnes per hour). The furnace is the main consumer of energy at the RM500 fuelled with a mixture of natural gas and vertical shaft gas. In 2012, the furnace burnt around 2.14 GJ/t of fuel (and 1.7 GJ/t of natural gas). The furnace is charged via a feeding grid and roller table at a rate of 1 billet every 50 seconds. Temperature is controlled manually by regulating the supply of fuel gas and combustion air (at a ratio of between 6 and 8:10 gas to air).The flue gas is measured at a single point at the main exhaust and analysed to control oxygen and CO levels. Combustion air is preheated by the exchanger up to 400°C. Pressure is controlled by adjusting gates on the side walls. Resident time is controlled by the walking hearths (five fixed beams and four moving beams). The thermal efficiency was calculated at 39% based upon 2012 operational data.

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Appendix B – ESCO construction steel product brochures for beam, equal angles and channels (see overleaf)

95

Appendix C – CCM No.5 technical and product specification ESCo is constructing a new continuous casting line (CCM No.5). The equipment has been supplied by DANIELI. CCM No.5 is currently under construction and commissioning expected in the first half of 2015. The CCM No.5 equipments have already been manufactured and now are under installation in site. The new CCM No.5 will produce 1 million tonnes per year of low, medium and high carbon steels and high strength low alloy steels (about 90% low and medium carbon steels in total). The plant includes continuous caster, segment and mould repair shop, Tundish repair shop, billet cooling, conditioning, storage and dispatch section along with all associated services, utilities and systems. The technical specification of CCM No.5 is summarised in Table4. CCM No.5 has electromagnetic stirrer (EMS) devices built around the moulds. EMS significantly improves billet surface and volume quality and could reduce the need for certain quality control and visual inspection checks. Billets will be produced with cross sections of 150 x 150mm and 200 x 200 mm at lengths of between 6 to 12m. The product specifications are shown in Table5 including billet dimensions, casting speed and throughput. Casting speed ranges from 1.5 to 3.5 metres per minute and overall throughput from 164 to 215 tonnes per hour. Planned net operation time is 7200 hours per year. Side view and top view drawings are displayed in the Appendix D – CCM No.5 Product quality guarantees (see overleaf)

96

97

Appendix D.

Table4: Summary technical specification of CCM No.5. (2) No

Item

Value

1

Manufacturer

DANIELI

2

Model number

3BLC906 (Machine Type)

3

Continuous caster type

Curved

4

Radius

9 metres

5

No. of strands

6 strands

6

Billet cross section

Square

7

Mould type

1000 mm curved copper tube

8

Mould oscillator type

Hydraulic retractable

9

Electromagnetic stirrer (EMS) type

M-EMS (Mould)

10

Primary cooling device

Water cooled copper mould

11

Secondary cooling device

Water spray & air cooling

12

Billet cutting device

Automatic oxy fuel cutting machine

13

Casting type

Open stream and submerged casting

14

Ladle capacity

125 tonnes

Table5: CCM No.5 product specifications describing the billet dimensions, casting speed and throughput Group (No)

Cross Section

Length (m)

Casting speed (m/min)

Strand productivity (tonne/h)

CCM productivity (tonne/h)

(mm x mm) 1 OC

150 x 150

6 to 12

3.5

35.9

215.5

2 OC

150 x 150

6 to 12

3

30.8

184.7

2 SC

150 x 150

6 to 12

2.8

28.7

172.2

3 SC

150 x 150

6 to 12

2.6

26.7

160.0

1 OC

200 x 200

6 to 12

2.1

38.3

229.8

2 OC

200 x 200

6 to 12

1.9

34.7

207.9

98

2 SC

200 x 200

6 to 12

1.7

31.0

186.0

3 SC

200 x 200

6 to 12

1.5

27.3

164.0

OC = Open stream casting SC = submerged entry nozzle casting

99

Appendix D – CCM No.5 Product quality guarantees (see overleaf)

100

Appendix D – CCM No.5 technical drawings (see overleaf) Figure 6 : CCM No.5 technical drawing – top down view including temperatures and thermal loadings.

101

Figure 7: CCM No.5 technical drawing – side-on view.

102

Figure 8: CCM No.5 technical drawing – Lateral comb transfer

103

104

Appendix E – Technical description of RM500 billet heating furnace

The RM500 reheat furnace is a walking hearth type furnace with six firing zones, each fired with burners. The walking hearth can operate at two speeds where billet resident time is either 80 or 120 minutes. The existing process charges cold billets to the furnace and about 25°C and discharges at about 1250°C after a resident time of 120 minutes. F.1 Control and temperature regulation The temperature of the furnace is controlled manually by regulating supply of fuel and combustion air to each of the six zones and capable to be control automatically via the existing SIPART DR24 loop controllers. Temperature is measured using online thermal couplings installed in each heating zone. The air-fuel to air ratio is controlled based upon continuous measurement and analysis of the flue gas (particularly oxygen and CO composition). Currently only one flue gas analyser is installed at the main exhaust. The current level of automation is Level 1 (“Automation Level” based on the Siemens automation level definitions) and the software monitoring is CITECT SCADA/HMI ver. 6.01 rel. Combustion air is preheated to around 400°C. This current level of control may be is not favourable for hot charging. This introduces a difference in charging temperature of over 600°C and will require a more advanced control system to regulate temperature inside the furnace more accurately, including: •

Raised level of furnace automation to Level 1.5 (Advanced monitoring) include the written logics for prediction of required gas volume and air to gas ratio accordance to the inlet bloom temperature and CCM5 and rolling mill 500 stoppages – this will enable the temperature to be controlled automatically.

•

Installation of new radiation thermometer before charging the blooms to furnace.

The amount of shifts between hot and cold charging should be minimised to reduce fluctuations in temperature inside the furnace and the need for large adjustments in the supply of fuel and combustion air. F.2 Resident time and temperature normalisation Billets are currently resident in the RM500 walking hearth furnace for 120 minutes. This allows sufficient time for temperature to normalise throughout the entire billet volume. Billets are spaced closely together. The RM500 furnace can operate at either 80 or 120 minutes. However, according to ESCo, it is not possible to operate at 80 minutes resident time as this is not sufficient time for billet temperature to normalise. Further, according to ESCo, it is not possible to reduce resident time due to throughput/capacity restrictions of the rolling line and finishing process which would require significant modification. Normally, hot charging reduces resident times due to the reduced heating requirement of the billets. This achieves higher productively and substantial specific fuel saving. To overcome the normalisation issue when introducing hot charging, edge heaters are installed in the furnace to achieve normalisation and higher furnace throughput.

105

F.3 Throughput Furnace throughput and rolling capacity is around the 140 tonnes/hour. The maximum capacity of the 200 tonnes/hour is achievable by increasing walking speed and reducing resident time to 80 minutes. However, this would require additional modifications to the rolling mill to handle billets at this speed. Table 6- Technical description of RM500 billet heating furnace. No

Item

Description

1

Furnace function

heating of billets before rolling

2

Furnace type

heating furnace with walking hearth

3

Operating conditions

Continuous

4

Dimensions and mass of billets

Cross-section (mm)

150 x 150

200 x 200

Length (m)

10.7 to 12

10 to 12

Mass (tonnes)

1.85 to 2.07

3.07 to 5.68

5

Layout of billets on hearth as per width (pcs)

One

6

Quality of heated metal

Carbon steel, carbon structural steel, lowalloy steel, alloy steel with ultimate resistance in cold condition up to 100 kg/mm2

7

Temperature of metal heating (°C)

1150 - 1250

8

Temperature of metal charge

Cold

9

Furnace capacity (t/hr)

up to 200

10

Furnace Hearth Area

Area (m2)

13.1 x 33.37 = 437

Effective (m2)

197

11

Effective hearth tension (kg/m2.hr)

100

12

Maximum frequency of billets discharged (pcs/hr)

120

13

Minimum cycle of billets discharged (sec)

25

28

14

Horizontal stroke of walking hearth (mm)

300

400

15

Number of billets in furnace (pcs)

82

109

16

Number of billets in furnace (tonnes)

Up to 225

Up to 300

17

Fuel

Mixed natural gas - blast furnace and coke oven gas

18

Heat calorific value (kcal/Nm )

3300

19

Furnace heat capacity

100

3

Million kcal/hr

106

No

Item

Description

Nm3/hr

31000

20

Fuel specific consumption (kcal/kg)

500

21

Air consumption for furnace firing (Nm /hr)

110000

22

System of usage of outgoing combustion products

Air heating in exchanger

23

Air heating temperature (°C)

400

24

Temperature of combustion products

At delivery from furnace (°C)

1000

Behind exchanger (°C)

650

25

Pressure under roof in final heating zone (MMWC)

1.5

26

System of cooling furnace elements

water

27

Water consumption for cooling at 12°C (m3/hr)

Up to 360

28

Water consumption of scale of hydraulic removal 3 (m /hr)

100

29

Water pressure (at gauge pressure)

2.5

30

Furnace Burners(Radiation type)

88 # large size(300 m3/h)

3

150 # small size(150 m3/h)

107

Appendix F – RM500 furnace original side drawing

108

Appendix G – RM500 furnace control and automation and system

109

Appendix H – Possible hot charging layout and modified CCM No.5

110

Appendix I – What is hot charging? Hot charging normally involves charging temperatures of between 300 to 800°C directly from the continuous casting machine to the reheat furnace. Hot charging is normal practice in the steel industry and has several benefits including significant energy cost savings when compared to cold charging. The best available billet transfer technique is direct rolling of billets of around 900 to 1000°C directly to the rolling mill. This state-of-the-art technique removes the need for an expensive reheat furnace entirely being replaced by a smaller induction furnace (if necessary). Direct charging can be expensive to retrofit and is normally limited to new plants. Figure 8 presents a possible material flow in a plant allowing both cold charging and hot charging. An optimised production planning and control system to synchronise the production schedules of a steelworks and a rolling mill can achieve a hot charging share of over 60% at about 800°C. Figure 8: Example plant layout of a cold and hot billet handling system.

111

Appendix J – Preliminary list of equipment, supplies and services No.

Description of work 1

Engineering and design services

2

Procurement

2.1

Quantity

including basic and advanced engineering, and documentation and manuals

Assumes use of CCM No.5 control room, process electrical system, process safety/environmental systems, work shop and utility systems (Firefighting, water ,Instrumentation AIR ,LV Power etc) and also the furnace room and post no.1 and PCY-1 Electrical room of rolling mill 500.

Equipment

2.1.1

Mechanical and Hydraulic equipment

2.1.1.1

Billet cross transport table

1 set

2.1.1.2

Lifting gear (hydraulic)

2 sets

2.1.1.3

Rollers

24 sets

2.1.1.4

Billet cross transport table

1 set

2.1.1.5

Modifications to CCM No. 5 cross transfer system

2.1.1.6

Quality inspection billet handling system

2.1.2

Includes rejection and additional cross transport tables

Process electrical systems Electric motors & drives

2.1.3

24 gear motor sets

Automation and control

2.1.3.1

Process control automation system

1 set

2.1.3.2

Quality inspection automation and control equipment

1 set

2.1.4

Comments

Other (e.g. Billet insulation)

2.2

Bulk materials

Excluded

2.3

Supply of first fills

includes one year of operating consumables

2.4

Supply of spare parts

includes commissioning, fast wearing and operational spares for mechanical, electrical, instrumental, automation & control equipment, communication

112

No.

Description of work

Quantity

Comments systems spares etc.

3

Transportation & related costs

4

Construction

4.1

Site establishment

4.2

Pilling, Foundation, Civil works Execution

4.3

Plant erection (Building steel structure etc)

4.4

Equipment installation (plant and utility equipment)

4.5

Commissioning & startup

4.6

Performance test

5

Management & Supervision services

6

Training Services (onsite training)

7

Production assistance

DAP INCOTERMS TERM

Excluded

E.g. project management, site management, technical assistance & engineering, construction engineering, Commissioning & performance test supervision

113

Appendix K – Site Photographs (see overleaf)

114

Appendix M – Definition of the scope of supply The detailed scope of work between Employer & Supplier is mentioned in the Following table split of work:

BD: Basic Design - Means the figures and design basis necessary for development of basic engineering, including main specification, main description and general data. BE: Basic Engineering - Means the design basis for the development of detailed engineering, including arrangement drawings, schematic diagrams, specific data, basic functional descriptions, basic media and power requirements, basic specifications for procurement. DD: Detail Design - Means the design activities providing all the necessary information for the equipment and material procurement and manufacturing.

SUP: Supply and Manufacturing Means the supply of equipment and materials

-

ER: Erection, Means the erection work for the actual assembly and erection on-site of equipment and materials.

-

CO: Commissioning Means the personnel handling the commissioning of the equipment and materials.

-

SV: Supervision

-

Means the specialized Supervisory services to be rendered for erection and commission of the equipment and materials.

LEGEND S:

Contractor

E:

ESCo

L: Local Contractor (Will be selected by ESCo in future)

115

ITEM

QTY.

BD

BE DD

SUPPLY

ER

CO SV

EQUIPMENTDENOMINATION

1 1.1

1.2

Mechanical and hydraulic equipment Modifications of CCM No. 5 cross transfer system and comb transfer system Steel structure of Collecting and Billet cross transport table

S

S

S

L

L

E/S

S

S

S

S

L

L

E/S

S

1.3

Steel structure of Pulling mechanisms

S

S

S

L

L

E/S

S

1.4

Steel structure of Lifting/rotating equipment

S

S

S

L

L

E/S

S

1.5

Steel structure of Pushing machine

S

S

S

L

L

E/S

S

1.6

Steel structure of Intermediate storage table 1

S

S

S

L

L

E/S

S

S

S

S

L

L

E/S

S

1.7 Steel structure of Billet cross transport equipment 1

1.8

Steel structure of Roller Tables

S

S

S

L

L

E/S

S

1.9

Quality control system

S

S

S

S

L

E/S

S

1.10

Steel structure of Billet cross transport equipment 2

S

S

S

L

L

E/S

S

1.11

Steel structure of Intermediate storage equipment 2

S

S

S

L

L

E/S

S

1.12

Steel structure of Reject table

S

S

S

L

L

E/S

S

1.13

Steel structure of Billet cross transport equipment 3

S

S

S

L

L

E/S

S

1.14

Hydraulic unit and equipments( all hyd, cylinder and accessories included )

S

S

S

S

L

E/S

S

1.15

Hydraulic components and accessories on board

S

S

S

S

L

E/S

S

1.16

Oil and grease lubrication system and accessories included

S

S

S

S

L

E/S

S

1.17

Compress air system and accessories included( in battery limits)

S

S

S

S

L

E/S

S

1.18

All gear boxes , gear motors , bearings ,seals, ropes, chains, wheels , … and all other catalogue items of all mechanical equipment base on Appendix N – Definition of Contractor Vendor list

S

S

S

S

L

E/S

S

116

ITEM

QTY.

BD

BE DD

SUPPLY

ER

CO SV

EQUIPMENTDENOMINATION for all items of Scope of supply

2

Process electrical system

2.1

All Electric motors & drives and components

S

S

S

S

L

E/S

S

2.2

Electrical panels and desk

S

S

S

S

L

E/S

S

2.3

Earthing system

S

S

S

L

L

E/S

S

2.4

Interconnecting cabling (cable list , terminal list,…)

S

S

S

L

L

E/S

S

2.5

Steel cabins for switchboards and pulpits

S

S

S

L

L

E/S

S

3

Process automation and control systems

3.1

Process control automation and components

S

S

S

S

L

E/S

S

3.2

Quality inspection equipment

S

S

S

S

L

E/S

S

S

S

S

S

L

E/S

S

automation

and

control

Field instruments devices and accessories 3.3 and components 3.4

Interconnecting cabling (cable list , terminal list,…)

S

S

S

L

L

E/S

S

3.5

Material Tracking

S

S

S

S

L

E/S

S

4

Other

4.1

Transportation and delivering of equipment (DAP term)

S

S

S

S

L

E/S

S

4.2

Steel Structure

S

S

S

L

L

E/S

S

4.3

Civil Work

S

S

S

L

L

E/S

S

4.4

Billet insulation

S

S

S

L

L

E/S

S

4.5

Any modification on RM500 Reheating furnace or add new equipment (Mechanicals, Electricals,

S

S

S

S

L

E/S

S

117

ITEM

QTY.

BD

BE DD

SUPPLY

ER

EQUIPMENTDENOMINATION

Automations and...) 4.6

Commissioning spare parts

S

S

S

S

includes commissioning, fast wearing and operational spares for mechanical, electrical, instrumental, automation & control equipment, communication systems spares etc.

4.7

Spare parts for 1 year normal operation

S

S

S

S

4.8

first fills

S

S

S

S

4.9

Fill up for 1 year normal operation

S

S

S

S

4.10

Supervision on Commissioning & starting up

S

4.11

Performance test

S

4.12

Management & Supervision services

S

4.13

Training

S

5

Documentation

5.1

General Layout

S

S

5.2

Calculation Report of billet temperature from CCM to RHF

S

S

5.3

Calculation report for improve quality of production and energy saving

S

S

5.4

Electrical and Automation engineering

S

S

S

S

5.5

mechanical engineering

S

S

S

S

5.6

Manuals(Operation, Erection)

S

S

5.7

civil work (Foundation mechanical equipment

structure)

S

S

S

S

5.8

Hot and Cold charge procedure for Exist Reheating

S

S

S

S

interference,

and

steel

Specials,

118

CO SV

ITEM

QTY.

BD

BE DD

SUPPLY

ER

EQUIPMENTDENOMINATION

Furnace mill 500

119

CO SV

Appendix N – Definition of Contractor Vendor list

Description

Brand

Country

Electric gear motors

BAUER

(Germany)

FLENDER

(Germany)

ROSSI

(Italy)

FIMET

(Italy)

FLENDER

(Germany)

TYSSEN

(Germany)

ROSSI

(Italy)

FIMET

(Italy)

FAG

(Germany)

SKF

(Sweden)

RKB

(SWISS)

NSK

(Japan)

Rolls

SANDVIK

(Sweden)

Seal ring ( v & u Ring )

ECONOMOS

(Austria)

Trelleborg

(Germany)

MAINA

(Italy)

FLENDER

(Germany)

Swivel joints

DEUBLIN

(Germany)

Hydraulic cylinders

PARKER

(USA)

REXROTH

(Germany)

REXROTH

(Germany)

Allweiler

(Germany)

Wickers

(Germany)

ATOS

(Europe)

Gear Boxes

Bearings

Couplings

Hydraulic components (pumps, valves, valve blocks)

120

PARKER

(USA)

Hydraulic Filters & Accessories

HYDAC

(Europe)

Accumulator

HYDAC

(Europe)

Separator & Heat exchanger

Alfa laval

(Italy)

Greasing components

DROPSA

(Italy)

Lincoln

(Europe)

PARKER

(None Chinese)

Festo

(None Chinese)

Others

(Famous-None Chinese)

ROSS

(USA)

PARKER

(USA)

ALFLEX

(Italy)

IWKA

(Germany)

SIEMENS

(Germany)

Endress & Hauser

(Germany)

Emerson

(U.K./FR)

ABB

(Sweden)

INOFLEX

(Italy)

SIEMENS

(Germany)

Endress & Hauser

(Germany)

Emerson

(U.K./FR)

ABB

(Sweden)

INOFLEX

(Italy)

SIEMENS

(Germany)

Endress & Hauser

(Germany)

Krohne

(Germany)

Pneumatic cylinders

Electro-valves

Expansion joints

Pressure & Diff. Pressure Transmitter

Temperature Transmitter

&

Flow Transmitter

Diff.

Temperature

121

Foxboro

(Germany)

Bourdon

(Germany)

Ruger

(U.K./FR)

Ashcroft

(Germany)

WIKA

(Germany)

CROSBY

(U.K.)

SIEMENS

(Germany)

Emerson

(U.K./FR)

Endress & Hauser

(Germany)

Yokogawa

(Japan)

I/P Converters

SIEMENS

(Germany)

Pneumatic actuators

STI

(Italy)

Fisher

(USA)

R.A. SYSTEM

(Italy)

SIEMENS

(Germany)

BALLUF

(Germany)

Honey Well

(USA)

SIEMENS

(Germany)

TeleMechanique

(Germany)

Magnetrol

(Italy)

Vega

(Germany)

Endress & Hauser

(Germany)

Foxboro

(Germany)

Jucker

(U.K.)

Mercoid

(U.K.)

Mobrey

(U.K.)

Vega

(Germany)

Press. & Temp.(Plus Electro Contact) Gauge

Orifice Plates & Flanges

Electric servomotors

Limit switches

Level switches

Level Transmitter

122

Endress & Hauser

(Germany)

Phoenix

(Germany)

Bonetti

(Italy)

TC KLINGER

(Europe)

IFM

(Germany)

Kobold

(Germany)

Emerson

(U.K./FR)

Endress & Hauser

(Germany)

Krohne

(Germany)

DANFOSS

(Germany)

Tele Mechanique

(Germany)

WIKA

(Germany)

DANFOSS

(Germany)

DANFOSS

(Germany)

SIEMENS

(Germany)

IFM

(Germany)

Kobold

(Germany)

Tabriz Pajoh

(Iran)

SICK

(Germany)

DELTA

(France)

ABB

(Sweden)

SIEMENS

(Germany)

FLENDER

(Germany)

Electrical ON/OFF Valve

AUMA

(Germany)

Electrical Control Valve

AUMA

(Germany)

Frequency Converters

SIEMENS

(Germany)

ABB

(Sweden)

Gauge glass

Flow switches

Pressure switches

Temperature switches

Proximity switches

Photocells

Electric motors

123

Electric breakers

ABB/SACE

(Italy)

SIEMENS

(Germany)

SIEMENS

(Germany)

Tele Mechanique

(Germany)

ABB

(Sweden)

SIEMENS

(Germany)

Tele Mechanique

(Germany)

ABB

(Sweden)

SIEMENS

(Germany)

SCHRACK

(Germany)

Finder

(Europe)

Thermal Relay

SIEMENS

(Germany)

Speed Monitor

SIEMENS

(Germany)

Borna

(Iran)

Over Load Monitor

Borna

(Iran)

Signal lamps

SIEMENS

(Germany)

Tele Mechanique

(Germany)

Famous Producers

(Iran)

SIEMENS

(Germany)

Tele Mechanique

(Germany)

SIEMENS

(Germany)

Tele Mechanique

(Germany)

Daniel

(U.K.)

Satam

(France)

Isoil

(Italy)

Petrol

(Italy)

Endress & Hauser

(Germany)

Contactors

Circuit Breaker(MCB, MCCB, ACB)

Relays

Push buttons

Selector Switch

Metering System

124

Panel Heating & Cooling Devices

RITTAL

(Germany)

PLC/RP/PDP/CP/R.I.O./MCC/UPS/IPC PANEL

RITTAL

(Germany)

SIVACON

(Germany)

SIEMENS

(Germany)

SAMSUNG

(Korea)

P.L.C.s

SIEMENS S7

(Germany)

PID Controller

Yokogawa

(Japan)

Foxboro

(Germany)

Eurotherm

(U.K.)

SIEMENS

(Germany)

ABB

(Germany)

H&B

(Germany)

Yokogawa

(Japan)

Foxboro

(Germany)

Eurotherm

(U.K.)

PEPPERL+FUCHS

(Germany)

PHOENIX CONTACT

(Germany)

Endress & Hauser

(Germany)

WAGO

(USA)

SENEKA

(Italy)

SIEMENS

(Germany)

ABB

(Sweden)

Schneider

(Europe)

Emotron

(Europe)

Rittal

(Germany)

Chloride

(Europe)

Schneider

(Europe)

TV camera

Indicator

Isolating/Barrier & Amplifier

DRIVE

UPS

125

Battery

Battery Charger

Steel Valve

Supervision P.C.

Saft Nife

(Europe)

Merlin Gerin

(France)

Legrand

(Europe)

EAM

(Italy)

Saft Nife

(Europe)

VISION

(China qualified)

YUASA

(Japan)

Merlin Gerin

(France)

GUTOR

(France)

SIEMENS GROUP

(Europe)

SICE

(Italy)

SOCOMEC

(France)

Chloride

(Europe)

Schneider

(Europe)

PARKER

(Germany)

VEE-LOCK

(Korea)

IBM DELL HEWLETT-PACKARD

P.C. monitor

IBM DELL HEWLETT-PACKARD

Supervision programme

SONY

(Japan)

SAMSUNG

(Korea)

LG

(Korea)

Win CC

126