Pt.kri Design And Engineering Standard(posco).pdf

Design and engineering standard Document code Item Project Country Customer Plant PBS

FBS

Count No Document code Revision No Date

00

2016.03.24

Description Ferro-nickel production plant Indonesia KAJIN GROUP Non-Ferrous General Engineering Common Manual and reference information Design and engineering standard -

Code IDN KRI AZ 000 E Z 600 655 010

Description

Prepare

Review

Approve

First issue

Kim

Seong

Sin

Table of contents Chapter 1 Piping Chapter 2 Crane Chapter 3 Belt Conveyor Chapter 4 Hydraulic Equipment Chapter 5 Cooling Tower Chapter 6 Dust Collectors Chapter 7 Electrical Equipment Chapter 8 Instrumentation Chapter 9 Process Computer Chapter 10 Communication Chapter 11 Civil and Architecture Chapter 12 Refractories Chapter 13 Safety Facilities Chapter 14 Pumps Chapter 15 Pressure and Non pressure Vessels

Chapter 1 Piping

Chapter 1 Piping

1-1

Chapter 1 Piping

Table of Contents 1.0 General ........................................................................................................... 3 1.1 Scope of application ........................................................................... 3 1.2 Scope of supply ..................................................................................... 3 2.0 Design conditions ........................................................................................ 5 2.1 General .................................................................................................... 5 2.2 Design standards and regulations ..................................................... 4 3.0 Engineering services and supervision...................................................... 5 4.0 Painting · coloring · packing..................................................................... 5 5.0 Design criteria ............................................................................................... 5 5.1 General .................................................................................................... 6 5.2 Low-pressure gas (BFG, COG, CFG, LDG) piping ......................... 8 5.3

Air pipe for oxygen, nitrogen and compressed air ......................... 10

5.4 LPG and LNG piping ......................................................................... 11 5.5 Steam piping .......................................................................................... 13 5.6 Fresh water and clear water piping.................................................... 14 5.7 Heavy oil piping .................................................................................... 14 5.8 Pipe racks ................................................................................................ 15 6.0 Fabrication and inspection standards ...................................................... 16 6.1 General .................................................................................................... 16 6.2 Mechanical items ................................................................................... 15

1-2

Chapter 1 Piping

1.0 General 1.1 Scope of application 1.1.1

This standard are applicable to the piping for supplying the iron mill utilities--BFG(Blast Furnace Gas), LDG(Linz Donawitz Gas), oxygen, nitrogen, compressed air, LPG(Liquefied Petroleum Gas), LNG(Liquefied Natural Gas), steam, fresh water, clear water and heavy oil--and to the general matters connected to the design, manufacture, test and inspection and the supply of the related facilities.

1.1.2 This standard does not cover piping for hydraulics, lubrication and process fluids such as those involved in coke by-product processing, air separation plant, chemical water treatment etc. For such piping, the standards are covered in the particular technical specifications for concerned units. Storm water drains and other open type sewerage systems and sanitary sewage from toilets, canteens, showers, comfort stations, drinking fountains, etc are also not covered in this standard.

1.2 Scope of supply 1.2.1 Range of supply (1) Unless explicitly specified otherwise for in KRI’s purchase specifications, Part 2 Estimation, ISZ-1 shall be applied. (2) The following pipes, valves and fittings (including counter flanges & jointing material) connecting up to the piping TOP (take over point) shall be provided by the supplier. 1) If the unit system is provided: Up to the first valve installed on the unit system Unit system Supplier

2) If the unit equipment is provided:

1-3

KRI

Chapter 1 Piping

Up to the point 1m from the exterior wall of the area where the unit equipment is installed Unit equipment

Exterior wall

Supplier

KRI

3) If the connecting pipe is provided between utilities, the supplier

shall provide products within the TOP range. Supplier’s range of supply

KRI

KRI

KRI

(3) Unless explicitly specified otherwise in the purchase specifications,

connecting pipes between the main pipe TOP and the unit equipment TOP shall be provided by the supplier. In general, utility lines shall run along the shop columns. Utility TOP shall be at +1200 mm above mill floor level at the nearest column. Complete pipework from TOP to consumer points of the equipment shall be in the scope of supplier. Main pipe Unit equipment Supplier

KRI

(4) A pipe layout drawings showing pressure, flow rate and pipe diameter at

each TOP shall be submitted. 1.2.2

Items not included in the range of supply General items not included in the range of supply, yet to be subject to prior a approval by KRI, are as follow: (1) Detailed programme and work plan on Installation works (2) Tools, temporary construction materials and temporary equipments used for installation works

1-4

Chapter 1 Piping

(3) Temporary lighting and expendable items used for operation and

maintenance (4) Electricity and general utility required for installation and commissioning 2.0 Design conditions 2.1 General Design conditions shall be governed by the provisions of Part 4 Design conditions, ISZ-1. 2.2 Design standards and regulations 2.2.1

Applicable laws and regulations High-pressure Gas Act, LPG Business Act, City Gas Business Act and Industrial Safety and Heath Act shall be applied. The related laws, regulation and acts are as follows :

2.2.2

Applicable standards Where Indonesia Standards are not available, the Standards of American National Standards Institute (ANSI), American society for Testing and Materials (ASTM), American Water Works Association (AWWA) or other equivalent to national standards for piping of the country of origin shall be used as per contract for design and construction of piping with the approval of the KRI.

3.0 Engineering services and supervision 3.1 Engineering services and supervision shall be governed by the provisions of Part 3 Engineering, ISZ-1. 3.2

All piping shall comply with the statutory requirements of the Government of Indonesia. Wherever required by mandatory Regulations, the successful supplier will have to obtain the approval of the relevant government agencies/statutory authorities.

4.0 Painting , coloring and packing Painting, coloring and packing shall be governed by the provisions of Part 5 Painting, coloring and packing, ISZ-1. 5.0 Design criteria

1-5

Chapter 1 Piping

If it is difficult or irrational to apply these design criteria, such fact shall be submitted to KRI. in writing for prior approval by KRI. 5.1 General 5.1.1

Material selection Pipe, valve and fitting installed above ground or inside buildings shall be selected based on information in Attachment 1.

5.1.2

Pipe thickness The pipe thickness shall be calculated according to the related domestic laws and regulations, and decided allowing for at least 1mm~3mm of corrosion allowance resulting from fluid. The corrosion allowance may not be considered for materials that not so much affected by corrosion.

5.1.3

Design load Design load shall be governed by the provisions of Part 4 Design conditions.

5.1.4

Insulation Type and thickness of utility insulating material per the installation location of piping shall be governed by the construction specification of KRI.

5.1.5

Standards of joint and connection (1) The height of pipe crossing over railroad or road shall be governed by the provisions of Chapter 11 Civil and Architectural Works, ISZ-2. (2) The bending radius of curvature of piping shall be 1.5 or more times the pipe’s outer diameter. If, however, 1.5 times cannot be applied due to narrowness of the place of installation, 1.0 time may be applied. (3) For locations where inspection is required, such as automatic valves and meters installed at a location 2.5m or above from the maintenance level, operation platforms or ladders shall be installed. (4) Valves shall be installed in such a way that the operation of overall facilities may not be interrupted due to inspection or maintenance. (5) Expansion joints, loop or other equipments having similar function shall be installed on the piping system to absorb thermal expansion or contraction resulting from temperature change. (6) For pipes exposed to vibration or impact, appropriate device capable of absorbing such vibration or impact shall be installed or the pipes shall be firmly supported. (7) Pressure testing procedures, conditions or other necessary items shall be

1-6

Chapter 1 Piping

(8) (9)

(10) (11)

(12)

(13) (14)

(15) (16) (17) (18)

(19)

specified and submit to KRI within 1.5month before execution.. Shoes used to support pipes shall be governed by the design standard drawings issued by KRI. The following standards shall be applied as a principle to connect steel pipe. However, flange or thread joints may be used on the spot where valves are attached or maintenance is required. 1) Pipe diameter ≤ 40A : Socket welding 2) Pipe diameter ≥ 50A : Butt welding For the piping design and the scope of supply at TOP, refer to Attachment 2. To make branch pipes from the main piping, commercially available tee shall be used. However, if commercial products are not available, branch pipes may be fabricated according to the KRI design standard drawings. If there is a possibility that pressure inside the piping exceeds the operating pressure, safety valves must be installed according to related laws and regulations to protect peripheral equipment. Strainers shall be installed on the inlet side of reducing valves and ect, that may be affected by foreign matters to deterioration of performance. If a pipe passes through the wall or floor, or if the buried pipe is likely to be damaged by a load, a pipe sleeve must be buried. If a pipe passes through a water tank, a water stop plate shall be installed. The size of the pipe sleeve shall be 1 or 2 step larger than the main pipe. A piping support shall be installed at an appropriate location so that the load of equipment and/or valves is not directly applied to the piping. Check valves shall be set up where back flow is anticipated, and arrows shall be marked on the valve body to indicate the direction of fluid. Appropriate signs shall be installed to indicate the buried pipe according to related laws and regulations to protect the buried pipe. The piping that passes below of roads or railroads shall be equipped with protective sleeves to prevent direct exposure to load and vibration of vehicles, and the sleeves shall be wider than the width of the roads or railroads by at least 1m each side. Top of sleeve shall be minimum 1.0 M below the road surface level.. Lubrication-free and grease-free pressure gauges shall be installed at an appropriate location of the piping below 10kg/cm2. The pressure gauges shall be calibrated within the range of 1.5~2.0 times of applied pressures.

5.2 Low-pressure gas(BFG., COG, CFG, FOG, LDG) piping 5.2.1 Fluid characteristics (1) BFG(Blast Furnace Gas)

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Chapter 1 Piping

1) Chemical component

Ingredient

CO

CO2

H2

N2

Volume( %)

22

20.7

3.2

54.1

2) Specific gravity : 1.05 3

3) Caloric value : 750 kcal/Nm

4) Range of explosion : 36 ~ 72%(of air) 5) Flash point : 650C (2) COG(Coke Oven Gas) 1) Chemical component

Ingredient

CO2

CmHn

O2

CO

CH4

H2

N2

Volume ( %)

3.1

2.9

0.3

8.4

26.6

56.4

2.3

2) Specific gravity : 0.36 3) Caloric value : 4,400 kcal/Nm3 4) Range of explosion : 5 ~ 28%(of air 5) Flash point : 600C (3) CFG(Corex furnace Gas) 1) Chemical component

Ingredient

CO2

CO

CH4

H2

N2

Volume (%)

33

43

1

21

2

2) Specific gravity : 0.95 3) Caloric value : 1.768 kcal/Nm3 4) Range of explosion : 13 ~ 69%(of air) 5) Flash point : 630C (4) LDG(Linz Donawitz Gas) 4) Chemical component

Ingredient

CO2

CO

H2

N2

O2

Volume %

17.8

64.2

2

15.9

0.1

4) Specific gravity : 1.05 4) Caloric value : 2,000 kcal/Nm3 4) Range of explosion : 18 ~ 75%( of air) 4) Flash point : 650C

(5) FOG Gas(Finex Off Gas)

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Chapter 1 Piping

1) Chemical component Ingredient

CO2

CO

H2

H2O

CH4

N2

Volume %

34

36

19

4

1.5

5.5

5.2.2

2) Specific gravity : 3) Caloric value : 1,150 kcal/Nm3 4) Range of explosion : %( of air) 5) Flash point : C Flow velocity calculation standards The standard flow velocity of the main pipe for each type of fluid is as follows; However, the flow velocity that is different from the standard flow velocity may be used due to the reasons of special system characteristics and economical efficiency. Standard flow velocity: 10 ~ 20 m/s (For Gas)

5.2.3

Standards of joint and connection (1) Carbon steel pipe (Seamless & ERW Type) shall be used for pipes with the diameter of 500A or less, and carbon steel plate (spiral Welded) to fabricate pipes with pipe diameter greater than 500A or bent pipe based on the KRI’s design standard drawings. (Refer Attachment-1) (2) Flange and blind flange shall be used for size pipes with diameter 500A or

less according to the standards of Indonesia’s shall be used for pipes with the pipe diameter of 600A or over and bent type based on the KRI’s design standard drawings. (Refer Attachment-1) (3) Pipe support 1) The maximum deflection of the pipe shall be 25mm. 2) Fixed, expansion, or sliding support shall be used selectively to support large pipes according to each situation. ① Fixed support Installed at the fixed point of pipe with a 4-leg structure to enable maintenance of the horizontal force resulting from thermal expansion. ② Expansion support Installed at a place requiring expansion support with a 4-leg structure to support both ends of bellows. ③

Sliding support

1-9

Chapter 1 Piping

Installed between the fixed support and expansion support with a two-leg

(4) (5)

(6) (7)

(8)

structure to set appropriate supporting space in consideration of the axial load. The saddle used to support the pipe shall be fabricated according to KRI’s design standard drawings. Reinforcing rings shall be installed according to KRI’s design standard drawings on points where supports are set up to protect the pipe from excessive load. Bellows type expansion joints made from stainless steel shall be installed to absorb thermal expansion and contraction of the pipe. Air and gas vents shall be installed on both ends of the pipe and the stop valve, or at other appropriate places if they are not a waterproof type. Air vents shall be installed with a sufficient high to discharge gas safely. Drain pipes and seal pots shall be installed at the lowest point of the pipe, the upper part of the expansion joints and orifice or other required places. The seal pots shall be fabricated according KRI’s design standard drawings. The drain pipes of the Seal Pot shall be located according to Indonesia Law and

Regulation.. (9) Exhaust valves for air and gas shall be applied as shown in Attachment 3. (10) Explosion vent shall be applied as shown in Attachment 4. (11) To shut off gas flow, water seal valves shall be installed at appropriate places. The water seal valves shall be fabricated according to KRI’s design standard drawings. (12) To gain an easy access to the inside of the large gas pipe, manholes and ladders shall be installed. 5.3 Air pipes for oxygen, nitrogen and compressed air shall read as Pipes for oxygen, nitrogen and compressed air. 5.3.1 Fluid characteristics (1) Oxygen 1) Pressure : Max. 25 kg/cm2 2) Temperature : 40 ℃ (2) Nitrogen 1) Pressure : Max. 7 kg/cm2 2) Temperature : 40 ℃ (3) Compressed air

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Chapter 1 Piping

1) Pressure : Max. 7 kg/cm2 2) Temperature : 40 ℃

5.3.2

Flow velocity calculation standards The standard flow velocity of the main pipe for each type of fluid is as follows. However, the flow velocity that is different from the standard flow velocity may be used due to the reasons of the special system characteristics and economical efficiency. (1) Standard flow velocity of oxygen and compressed air pipe : 10 ~ 15 m/s (2) Standard flow velocity of nitrogen piping : 25 ~ 30 m/s

5.3.3

Standards for joints and connections (1) The piping shall be designed pursuant to the provisions of the domestic gas related laws. (2) The bending radius of the oxygen pipe shall be 1.5 or more times the outer diameter of the pipe. (3) In case of oxygen piping, valves, fittings and straight pipes shall be provided with explosion-proof and fire-proof treatment. (4) To weld steel pipes to copper pipes, or copper pipes to copper pipes, argon welding shall be used at the fabrication plant. (5) The oxygen piping shall first be cleaned through pickling, neutralization, and steam cleaning before being washed with a proper type of volatile detergents. (6) Prior to assembling after fabrication, valves shall be cleaned with appropriate type of detergent to remove oil completely. Valves shall be assembled after drying, and be totally closed to prevent ingress of oils and dust. The same procedures shall be applied for pipes as well. (7) The bending of the oxygen pipe shall be made by high frequency method.

5.4 LPG and LNG piping These standards are applicable to the gas piping that supplies LPG and LNG from outside. Refer to pressure related laws and regulations of Indonesia’s Industry Safety. 5.4.1

Fluid properties (1) LPG (Liquefied Petroleum Gas) (Attachment-5)

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Chapter 1 Piping

1) Chemical composition 2) S

Ingredient C3H8 O2 N2 C2H6 p Volume( %) 60.01 7.97 29.91 0.58 e cific gravity : 1.05 3) Caloric value : 13,803 kcal/Nm3 4) Range of explosion : 2.5 ~ 10.37%(of air) 5) Flash point : 500 ~ 600C (2) LNG(Liquefied Natural Gas) (Attachment-5). Ingredient

CH4

C2H6

C3H8

C4H10

Volume (%)

88.5

4.6

5.4

1.5

C3H6

C4H10

0.15

1.38

1) Chemical composition 2) Specific gravity : 0.655 3) Caloric value : 9,520 kcal/Nm3 4) Range of explosion : 4.61 ~ 13.55%(of air) 5) Flash point : 630 ~ 730C

5.4.2

Material quality selection For LPG and LNG pipe buried underground, P.E. coated steel pipes shall be used.

5.4.3

Flow velocity calculation standards The standard flow velocity of the main pipe for each type of fluid is as follows. However, flow velocity this is different from the standard may be used due to the reasons of special system characteristics and economical efficiency. Standard flow velocity: 10 ~ 15 m/s

5.4.4

Standards for joint and connection (1) LPG and LNG pipe shall be designed according to related laws and regulations, and shall be jointed by welding.(Refer Attachment-1) (2) The piping support shall be spaced according to Indonesian Law, Acts and regulation refer to 2.2. (3) Appropriate isolation pad shall be provided according to the related laws and regulations between pipes and supports. (4) Purge valves shall be installed at the front and back of the gas shut off valves.

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Chapter 1 Piping

Purge valve size

Medium-pressure pipe

Low-pressure pipe

50A

100A or more

150A or more

25A

Less than 80A

Less than 125A

(5) To prevent damage to the buried gas pipe during excavation work, a

warning tape indicating the name of fluid shall be buried along with the pipe as required by the related laws and regulations. In addition, protection devices shall also be installed for damage prevention. (6) Gas piping shall meet the requirements of Indonesia’s standard, and shall be erected as per ANSI B 31.2 / B 31.4 or equivalent. Care shall be taken that all parts as erected shall be free of oil, grease, scale and dirt. (7) Exposed pipelines shall not be erected under or near high voltage overhead power lines. Underground pipelines shall not be installed in trenches or tunnels occupied by power lines. Valves shall not be placed in pits. 5.5 Steam piping 5.5.1 Fluid characteristics (1) Pressure : Max. 12 kg/cm2 (2) Temperature : 191℃ 5.5.2 Material quality standards For pipe buried underground, insulated steel pipe shall be used. 5.5.3

Flow velocity calculation standards The standard flow velocity of the main pipe for each type of fluid is as follows. However, flow velocity that is different from the standard flow velocity may be used due to the reasons of special system characteristics and economical efficiency. (1) Standard flow velocity of saturated steam : 20 ~ 30 m/s (2) Standard flow velocity of over-heated steam : 30 ~ 50 m/s

5.5.4 Standards for joint and connection (1) The Steam trap shall be horizontally installed to effectively discharge the condensate occurring inside the pipe. The condensate shall be discharged into drain absorber. (2) The piping system shall be provided with loops or other devices carrying the same function to absorb thermal expansion and contraction resulting from temperature change.

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Chapter 1 Piping

(3) Steam piping covered under Indonesia Regulations(IR) the provisions

of relevant clauses of IR shall be taken into account. The forces and moments occurring during expansion / contraction shall be determined by calculation.

5.6 Fresh water and clear water piping 5.6.1 Material quality selection The fresh water and clear water pipes and fittings to be buried underground shall use steel pipe with the inside coated with epoxy.(FW: Tar-epoxy, CW: Liquid-epoxy), and the outside with asphalt coating or PE wrapping.

5.6.2 Flow velocity calculation standards The standard flow velocity of the main pipe for each type of fluid is as follows. However, the flow velocity that is different from the standard may be used due to the reasons of special system characteristics and economical efficiency. Standard flow velocity : Supply 2.0 ~ 2.5 m/s, Return 1.5 ~ 2.0 m/s 5.6.3

Standards for joint and connection (1) To enable the suction pipe to satisfactorily suck water out of the water tank, the inlet shall be installed at a point of 1.25D or over from the wall and 0.75D or over from the bottom. (2) An eccentric reducer shall be used to prevent the formation of an air pocket when installing a reducer at the inlet or outlet of the pump. Direction of the installation shall be carefully chosen. (3) Short elbows shall not be used at the inlet of the pump, if avoidable. (4) Air vent valves or plugs shall be installed at places where air might be generated. (5) A chamber shall be installed in a place where the following equipment are to be placed. The minimum diameter of the chamber shall be 600mm. 1) Expansion joint 2) Valve 3) Flow meter 4) Final welding point 5) Other required places

5.7 Heavy oil piping 5.7.1

Fluid characteristics

1-14

Chapter 1 Piping

(1) Type : Bunker-C (2) Caloric value : 9,300kal/l

5.7.2 Flow velocity calculation standards The standard flow velocity of the main pipe for each type of fluid is as follows. However, the flow velocity that is different from the standard may be used due to the reasons of special system characteristics and economical efficiency. (1) Pipe diameter ≤25A : 0.5 ~ 0.9 m/s (2) Pipe diameter =32A ~80A : 0.7 ~ 1.0 m/s (3) Pipe diameter ≥100A : 1.0~ 1.6 m/s 5.7.3

Standards for joints and connections (1) Piping shall be designed to use steam tracings for the heating of heavy oil within the piping. (2) In order to prevent abnormal pressure rise within piping, relief valves shall be installed at the outlet of the heavy oil pump and at the bypass line to the tank. (3) The pipe shall be kept warm to prevent the solidification of heavy oil. (4) In case the outer surface has openings for flanges or pipe hangers, the internal heat insulation materials shall be treated with waterproof. (5) Pipe heating systems of steam tracing shall be suitably provided where the temperature of the fluid conveyed is to be kept above minimum desired values for process requirements or for reduction of viscosity. (6) The steam tracer lines shall be insulated together with the service line. The steam tracer lines shall be provided with adequate trap assemblies and other appurtenances.

5.8 Pipe racks In order to lay a number of pipes outside, a pipe rack of truss structure shall be installed according to the following standards. Cables may also be distributed on the pipe racks. (1) For installation height of the pipe racks, refer to Chapter 11 Civil and Architectural Works, Part 6, ISZ-1. (2) In case the pipe racks pass across a road, safety guards shall be constructed according to the KRI’s design standard drawings. (3) In case cables are installed inside the pipe racks, the rack shall be installed high enough to allow passage of technicians to construct or inspect. Cable tray cover

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Chapter 1 Piping

(4) (5) (6) (7)

shall also be installed to protect the cable from sunlight. If the piping and cables are laid together, the cables shall not be laid under the piping. 2-leg supports shall be used to support the pipe racks. However, 4-leg supports shall be used where load is concentrated. For more detailed information regarding the pipe racks, standards provided by KRI shall be referred to. All required operating platforms, valve stands, access ladders, handrails etc shall be erected complete, after the piping has been installed. Structural steelwork in connection with those items shall conform to the relevant Indonesian Standards for Structural Steelwork.

6.0 INSPECTION AND TESTING 6.1 General

6.1.1 All components of the piping shall be subjected to visual inspection and testing as per the relevant codes specified. Routine and type tests for various components shall be performed at the manufacturer’s works and test certificates including those for materials / equipment / accessories shall be furnished. 6.1.2 The procedure for inspection and shop testing of piping components at manufacturer’s works shall conform to the General Conditions of Contract and the Technical Specifications. 6.2 Tests at Site 6.2.1 Systems under vacuum conditions shall be tested at 1.5 kg / cm2 greater than the nominal external pressure of the system. 6.2.2 Expansion joints and / or other elements intended for absorbing stresses through directional movement shall be separately tested at 1.25 times the water

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Chapter 1 Piping

or the pipe test pressure, whichever is higher. 6.2.3 Valves, traps, strainers, separators etc shall be tested as specified / approved by KRI /guidelines stipulated in relevant SNI/International Code.. 6.2.4 Fire protection piping shall be tested as per statutory regulations for these services, as applicable. 6.2.7 For fuel gas piping, LP gas, hydrogen, oxygen and hydraulic system piping, radiographic / ultrasonic tests shall be carried out for welded joints as per relevant standards and Mandatory Regulations, as applicable and if specified in Technical Specification. Number of joints to be tested shall be as specified or as per relevant codes / standards. Radiographic / Ultrasonic testing of welded joints of steam lines, if required, shall be as per stipulations in Indonesian Boiler Regulations. Radiographic / ultrasonic tests for other lines shall meet The requirements of relevant SNI / ASTM codes or equivalent. Supplier’s scope of work shall include the certified interpretation of the results of radiographic / ultrasonic tests by a reconsinged and approved agency. Attachment 1. Pipe, Valve and Fitting materials

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Chapter 1 Piping

1.1 Pipe Fluids

1.

BFG, COG, CFG, FOG, LDG, MIXED GAS

Sizes (DN)

Standards/Codes as followed

150 & below

ERW pipes to SNI;

150 to 600

SNI:

2.

O2

Upto 600

Fabricated from plates or spiral Welded of specification SNI or ANSI : (LDG pipe: Paint Tar Epoxy 400μ within the range of 120˚ inside the pipe.) Seamless pipes to ASTM /API.

3.

PA, IA

150 and below

ERW pipes to SNI:

200 and above

ERW pipes to SNI:

150 and below

ERW pipes to SNI:

200 and above

ERW pipes to SNI:

All sizes

Seamless pipes to ASTM /API

Low pressure

All sizes

ERW pipes to SNI:

High pressure Steam *

All sizes

Seamless pipes to ASTM /API

Low pressure

All sizes

ERW pipes to SNI:

All sizes 150 and below

Seamless pipes to ASTM /API ERW pipes to SNI:

200 to 450

ERW pipes to SNI:

Above 600

4.

N2, Ar

Low pressure

High Pressure 4.

5.

6.

*

H2, LPG, LNG

High pressure Fuel oil

The pipes procured for steam service as per any national/international code, has to comply with the stipulations indicated in Indonesian Regulation (IR), in addition.

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Chapter 1 Piping

1). Acronyms for Piping -

BFG: BLAST FURNANCE GAS

-

LDG: LINZ DONAWITZ GAS

-

MIX GAS: MIXED GAS

-

O2: OXYGEN

-

IA: INSTRUMENT AIR

-

PA: PLANT AIR

-

H : HYDROGEN

-

N : NITROGEN

-

AR: ARGON

-

LNG: NATURAL GAS

-

LPG: PROPANE GAS

-

ST: STEAM

-

BO: BUNKER OIL

-

FW: FRESH WATER (COOLING WATER)

-

CW: CLEAR WATER

-

SW: SEA WATER

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Chapter 1 Piping

1.2 Fitting 1.0

BFG, LDG MIXED GAS

1.1

Screwed Fittings

1.2

Welded/Fabricated fittings Bends

Tees/ Reducers

1.3

Flanges

50 and below

No usage

50 and below

ASTM, ANSI/ with 1.5 D

65 and above

ASTM, ANSI /Mitred bend with 1.5 radius from pipe

50 and below

ASTM, ANSI

65 and above

ASTM, ANSI

Upto 2000

WN flanges to ASTM, ANSI

Above 2000

ASTM, ANSI

1.4

Gaskets

All sizes

SNI or ASTM, ANSI:

1.5

Bolting

All sizes

SNI or ASTM, ANSI:

2.0

O2

2.1

Fittings 50 and below

ASTM, ANSI / 1.5 D

65 and above

ASTM, ANSI /1.5 D

50 and below

ASTM, ANSI

65 and above

ASTM, ANSI/Fabricated

All sizes

ASTM, ANSI .

Bends

Tees / Reducers

Flanges

1-20

or Non-asbestos

Chapter 1 Piping

2.2

Gaskets

3.0

PA, IA, N2, Ar

3.1

Screwed fittings

3.2

Welded fittings Bend

Tees /Reducers

All sizes

LOX Gr. Teflon (Oil-free)

40 and below

SNI or : ASTM, ANSI

50 and below

ASTM, ANSI/1.5 D or LR

65 and above

ASTM, ANSI /1.5 D or LR

50 and below

ASTM, ANSI

65 and above

ASTM, ANSI/Fabricated

3.3

Flanges

All sizes

WN flanges to SNI: or ASTM, ANSI

3.4

Gaskets

All sizes

SNI: or ASTM, ANSI

3.5

Bolting

All sizes

SNI: or ASTM, ANSI

4.0

HP Steam * Upto 600

ASTM, ANSI

4.1

5.0

All fittings, gaskets, bolting LP & MP STEAM *

5.1

Fittings

All sizes

ASTM, ANSI

5.2

Gaskets

All sizes

SNI:

5.3

Flanges

All sizes

WN Flange to ASTM, ANSI:

6.0

FUEL OIL 40 & below

SNI: or ASTM, ANSI

6.1

Screwed fittings

1-21

or Metal

Chapter 1 Piping

6.2

Welded fittings Bends

Tee / Reducers

50 and below

ASTM, ANSI/ ASTM, ANSI

65 and above

ASTM, ANSI / ASTM, ANSI with 1.5

50 and below

ASTM, ANSI

65 and above

ASTM, ANSI/Fabricated

6.3

Flanges

All sizes

WN flanges to SNI: or ASTM, ANSI

6.4

Gaskets

All sizes

SNI or ASTM, ANSI

6.5

Boltings

All sizes

SNI: or ASTM, ANSI

*

The fittings procured for steam service as per any national/international code, has to comply with the stipulations indicated in Indonesian Regulation (IR), in addition.

1-22

Chapter 1 Piping

1.3 Fitting

1.

2.

3.

4.

BFG, COG, LDG, MIXED GAS Forged steel gate or CI taper plug valve (manufacturer's standard)

Isolation valves

All sizes (COG, CFG and Mixed Gas)

Throttling

All sizes (COG, CFG and Mixed Gas)

Butterfly valves (manufacturer's std.)

Isolation

All sizes

Ball valve (manufacturer's standard)

Non-return

All sizes

Manufacturer's standard

Isolation

All sizes

Ball valve (manufacture's standard)/SNI:

Throttling

All sizes

Ball valve (manufacture's standard)/SNI:

Non-return

All sizes

Ball valve (manufacture's standard)/SNI:

Isolation

All sizes

Ball valve (manufacture's standard

Throttling

All sizes

Non-return

All sizes

Ball valve (manufacture's standard Ball valve

O2

PA, IA, N2, Ar

H2, LNG, LPG

1-23

Chapter 1 Piping

(manufacture's standard 5.

STEAM * Isolation

50 and below

Above 50

Throttling

50 and below

Above 50

Non-return

6.

Cast steel gate as per manufacture's std., materials to ASTM Forged steel globe as per manufacture's std., materials to ASTM Cast steel globe as per manufacture's std., materials to ASTM Forged steel check as per manufacturer's std., materials to ASTM

Above 50

Cast steel check as per manufacture's std., materials to ASTM

Isolation

All sizes

SNI 10459 /Cast Steel taper plug type (Manufacturer's Standard)

Throttling

50 and below

FUEL OIL

Non-return

*

50 and below

Forged steel gate as per manufacture's std., materials to ASTM

Forged steel Globe as per manufacturer's std., materials to ASTM

65 and above

SNI; / Cast steel Globe as per manufacturer's std., materials to ASTM

50 and below

SNI /Forged steel check as per manufacturer's std., materials to ASTM

65 and above

SNI /Cast steel check as per manufacturer's std., materials to ASTM

The valves procured for steam service as per any national/international code, has to comply with the stipulations indicated in Indonesian Regulation (IR), in addition.

1-24

Chapter 1 Piping

Attachment 2.

Scope of pipe supply at TOP Scope of Supply Case "A"

Supplier

Case "B" User

Flange connection

Valve connection

Case "C"

Case "D"

Pipe connection

Case "E"

Case "F"

Thread valve connection

NO

구 분

Water seal valve connection

A

I

B

S t P

S ○

1

Companion

○

2

Bolt 및 nut & nut

○

3

Technical consultation & schedule

○

4

Test and inspection 시험 및 검사

5

Engneering data

e

P

S

D P

S

E P

S

F P

○

○

○

S

P

○

○

m

○ ○

C

○

○

○

○ ○

1-25

○

○ ○

Note) S:Supplier, P:KRI

○

○

○

○

○

○ ○

○

○ ○

○

Chapter 1 Piping

Attachment 3. Exhaust valve L L1

L2 L3

s drill

s drill

t

H

A

500

b

d C D h drill n ea

Nominal diameter 공칭직경 (d) 100 150 200 250 300

Note)

Flange

Lever A

D

C

t

b

n

200 265 335 385 435

165 230 270 325 375

11 18 20 20 20

19 19 19 19 22

8 8 8 12 12

150 200 250 300 350

Balance size

H

170 200 200 200 200

L

L1

L2

L3

S

1300 2100 2130 2350 2675

600 1000 1000 1200 1500

600 1000 1000 1000 1000

120 145 170 210 250

18 21 21 21 24

150 X 40t 150 X 40t 200 X 45t 250 X 42t 300 X 48t

Weight(kg) 중량 (kg) FC

SS

19.23 27.33 45.33 59.82 75.65

7.794 12.324 19.36 21.34 27.88

(1) The above specifications shall be applied to air and gas exhaust valves. (2) The flange used shall be Steel welding pipe flanges or 5kg/cm2 insert welding flange of equivalent standards. (3) The maximum operating pressure shall be 0.15 kg/cm2.

1-26

Chapter 1 Piping

Attachment 4. Explosion vent 1100 220

100

380

780

35^

A type

293

35˚

R

300

1100 220

100

35

o

308

780

B type

431

35˚

500

R

분 류 Type

Applicable 사용크기 size

Weight (kg) ) 중량 (㎏ Gray회주철 iron casting

Stainless Stainlesssteel 강

AA type 형

300 -- 500 300 500

21.22 21.22

49.573 49.573

BB type 형

600

21.22 21.22

111.298 111.298

(1) ThSNI specification SNI applicable to the explosion vent installed on the low-pressure gas

pipe. (2) R value of the explosion vent shall conform to the set value. Maximum pressure and blown-out pressure Maximum operating pressure

0.15 kg/cm2

Blown-out pressure

0.2 kg/cm2

1-27

Chapter 1 Piping

Attachment 5

FLUID PROPERTIES

1. LPG For composition refer SNI: Properties of major constituents are as per following: Propane 70 % propane 30 % propane Butane C3H8 30% butane 70% butane C4 H10 Molecular weight 44.09 48.30 53.91 58.12 Melting point, 0C

-190

-135

0

Boiling point C at 760 mm -42 Hg

-0.5

Critical temperature 0C

97

152

Critical pressure, bar

42

37

Ignition point, appx. 0C

520

500

Gravity (specific) in gaseous 1.52 state at 760 mm Hg and 150C (air=1)

1.67

1.86

2.01

Gravity (absolute) in gaseous 1.86 state at 760 mm Hg and 150C (g/ltr)

2.04

2.28

2.46

Density in liquid state at 0.51 150C

0.53

0.56

0.58

Specific heat at constant 0.40 pressure kcal/ kg gas in gaseous state

0.40

Kcal/kg gas in liquid state

0.55

Heat of kcal/kg

0.58

vapourization, 102

Gross calorific kcal/klg

value

92

, 12000

11900

11900

11800

11100

11000

11000

10900

Gross calorific value , 23000 kcal/m3, 150C, 760 mm Hg

25200

28200

30400

Net calorific value , kcal/m3, 21200 150C, 760 mm Hg

23200

26000

28000

Net calorific value , kcal/klg

1-28

Chapter 1 Piping

Octane Number

125

91

2.

LNG

A.

Natural gas available in Indonesia are dSNItributed in the gaseous form to consumers at certain parts of the country through cross country piping network. Indicative composition of Natural Gas as available in Indonesia SNI presented below with minimum and maximum contents as per different analysSNI:

N2

0.1

0.01

n.a

0.4

10.3

Estimation Vol.% 0.1

H2S

n.a

0

0.0006

n.a

n.a.

0.0005

CO2

0.9

4.76

5.12

0.03

0.25

1.0

O2

n.a

n.a

n.a

0.02

1.24

0.0

CH4

85.8

79

92

76.1

83.5

86.8

C2H6

7.2

5.12

7.7

2.6

10.1

7.0

C3H8

3.2

1.18

4.7

2.3

6.1

3.0

C4H10

1.8

0.1

2

1.4

2.4

1.8

C4H8

n.a

n.a

n.a

n.a

n.a

0.3

C5H12

0.7

0.0

0.5

0.1

1.6

-

C6+

0.3

0

0.03

0.1

1.3

-

Vol.%

AnalysSN I No.1 B.

Mol.% min.– max

Mol.% min.– max

AnalysSNI No.2

AnalysSNI No.3

Certain LNG terminals are being set up in the western coast of Indonesia. The sources of LNG are primarily from the Gulf countries like Qatar, Yemen etc.

1-29

Chapter 2 Crane

Chapter 2 Crane

2-1

Chapter 2 Crane

Table of Contents 1.0 General ........................................................................................................... 3 1.1 Scope of application ............................................................................. 3 1.2 Scope of supply ..................................................................................... 3 1.3 Drawings and documents .................................................................... 4 2.0 Design conditions ........................................................................................ 4 2.1 General .................................................................................................... 4 2.2 Design standards and regulations ..................................................... 5 3.0 Engineering services and supervision...................................................... 6 3.1 Engineering services ............................................................................. 6 3.2 Supervision............................................................................................. 6 3.3 Commissioning ...................................................................................... 6 4.0 Painting · coloring · packing ..................................................................... 7 5.0 Design criteria ............................................................................................... 7 5.1 Steel structure of crane ......................................................................... 7 5.2 Mechanical equipment ......................................................................... 8 5.3 Electrical equipment and instrumentation ...................................... 17 6.0 Fabrication and inspection standards ...................................................... 24 6.1 Field test at supplier manufacturing plant ....................................... 24 6.2 Crane manufacturing tolerance .......................................................... 24 6.3 Building Run Way Girder tolerance .................................................. 29 6.4 Overall test.............................................................................................. 31

2-2

Chapter 2 Crane

1.0 General 1.1 Scope of application This standard is applicable to general technical specifications used to purchase cranes, the major transporting means used by the steel making plant (overhead traveling cranes, mill cranes, charging cranes, ladle cranes, gantry cranes, and bridge cranes). 1.2 Scope of supply 1.2.1

Range of supply (1) Supply conditions and range shall be governed by the provisions of the purchase technical specifications or requirements provided by KRI. (2) Unless specifically provided for separately regarding the range of supply, Part 2 Estimation, ISZ-1 shall be applied in common. General range of supply is as follows: 1) Crane design, manufacture, inspection, and transporting ① Mechanical systems - Hoisting systems: Motor, reducer, coupling, brake, drum, sheave, wire rope, hook, etc. - Traveling systems: Motor, reducer, coupling, brake, traveling wheels, etc. - Horizontal traveling systems: Motor, reducer, coupling, brake, horizontal traveling wheels, etc. - Steel structures: Girder, saddle(end carriage), trolley frame, operation room, sidewalk and stairways, name plates, etc. - Others: Greasing systems, magnet, grab, etc. ② Electrical systems and instrumentation - Power & control cable - Sensors such as the hoisting, traveling, and horizontal traveling limit switches - Other electrical parts such as the lighting, alarms, warning siren, etc. 2) Engineering and supervision services for installation and operation 3) Submission of drawings and documents 4) Performance guarantee and warranty 5) Permits and licenses issued by government offices

1.2.2 Items out of the range of supply General matters out of the range of supply are as follows; however, such items shall be governed by the provisions of the KRI’s purchase specifications.

2-3

Chapter 2 Crane

(1) Installation works 1) Traveling rail installation works 2) Piping works 3) Civil and architectural works 4) Electricity and general utility required for installation and commissioning (2) Tools, temporary construction materials, and temporary equipment used

for installation works (3) Temporary lighting, and expendable items used for operation and maintenance (4) Test weight used for load tests 1.3 Drawings and documents General matters pertaining to the submission of drawings and documents shall be governed by the provisions of Part 2 Estimation, ISZ-1. 2.0 Design conditions 2.1 General 2.1.1 Design conditions shall be governed by weather and geographical conditions of the area where equipment is installed. Design conditions covering CILEGON areas in Indonesia shall be governed by the provisions of Part 4 Design conditions, ISZ-1. 2.1.2 Definition of load (1) Hoisting load The hoisting load means the maximum weight that can be lifted by the crane according to its structure and materials. (2) Rated load The rated load means the crane’s hoisting load from which the weight of lifting devices, such as the hooks, grabs and/or buckets, is subtracted. However, in case of a crane carrying jib and the hoisting capacity varies depending on the rake angle, the rated load shall be the value derived by subtracting the weight of the lifting devices from the hoisting load at that position. (3) Dead load The dead load means all loads with the magnitude and position of load applying to the crane structure and member being consistent. (4) Live load The live load means all loads, except the wind load, causing stress variance to the crane members. Stress may be changed by the position and the magnitude of the load externally acted or by the move of the crane structure itself.

2-4

Chapter 2 Crane

2.2 Design standards and regulations 2.2.1 The Cranes covered under this standard shall be designed, manufactured, assembled, tested, erected and commissioned in accordance with the latest edition of Indonesian Standards for the Crane taking due notes of the various requirements laid down in different parts / sections of this specification. 2.2.2

Wherever imported components are utilized, these shall be manufactured in accordance with the relevant standards and Codes of Practice published in the country where they are manufactured and after allowing for specific aspects under Indonesian conditions, such as tropicalisation etc.

2.2.3

All equipment shall also conform to the requirements specified in relevant Inter Plant Steel Standards (IPSS), wherever available.

2.2.4

The equipment shall also conform to the latest Indonesian Electricity Rules and Indonesian Factories Act as regards safety, earthing and other essential provisions specified therein for installation and operation of EOT Cranes including electrics.

2.2.5

All equipment shall comply with the statutory requirements of the Government of Indonesia.

2.2.6

KS, SNI, JIS, CMAA and the industrial standards of other countries may be applied. However, KRI’s prior approval is required in relation to the use of such standards. Such standards must, however, conform to the crane manufacturing standards, safety standards and inspection standards prescribed under the Industrial Safety and Health Act.

3.0 Engineering services and supervision 3.1 Engineering services General common matters shall be governed by the provisions of Part 3 Engineering, ISZ-1. Detailed range of application is as follows: 3.1.1

Basic design (BD) Designs used to decide specifications and drawings forming the basis of the

2-5

Chapter 2 Crane

equipment purchase, detail design and shop drawings based on the basis plan include the following: 1) Crane technical specification Rated capacity, lift, moving speed and distance of each part 2) Basic technical calculations Girder structural calculations and drive system technical calculations 3.1.2 Detail design (DD) Detail design means all design services performed based on the basic design, including the preparation of detail drawings and part layout plan covering the manufacture, installation and purchase of equipment. 3.2 Supervision 3.2.1

The supplier shall supervise field installation works performed using the supplied equipment and materials. (1) Technical description and advice related to installation works (2) Provision of guidance and advice with respect to transporting and unloading

3.2.2

The supplier shall attend commissioning after completion of installation works based on the commissioning plan approved by the owner to provide required guidance and advice. If necessary, the supplier shall conduct training for the operators and mechanics.

3.3 Commissioning 3.3.1

PAT (Preliminary Acceptance Test) Upon completion of installation work, the supplier shall, under the supervision of KRI, carry out independent or interlocked test under no-load and load status based on the PAT manuals prepared by the supplier to verify each equipment demonstrates its full capacity.

3.3.2

FAT (Final Acceptance Test) Upon completion of PAT, the supplier shall, under the supervision of KRI, carry out independent or interlocked test under load status based on the FAT manuals prepared by the supplier to verify equipment demonstrate their full capacity. The test cannot be carried out because there will not be adequate power provided in the workshop.

2-6

Chapter 2 Crane

4.0 Painting · coloring · packing Applicable standards shall be governed by the provisions of Part 5 Painting · coloring · packing, ISZ-1. 5.0 Design criteria This design criteria applies when preparing the basic and detail design in accordance with Paragraph 2.2 Design standards and regulations. 5.1 Steel structure of crane 5.1.1 General (1) The crane structure shall be designed, manufactured in line with various requirements laid down in relevant Indonesian standards and rules as indicated under clause 2.2. (2) The strength of the crane girder, saddle, trolley, and other steel structures shall be calculated according to the crane manufacture standards, safety standards and inspection standards of the relevant Indonesian standards and rules. (3) For cranes with rated load of 100 tons or higher, or other important cranes with load less than 100tons, the crane supplier shall submit computer-aided structural analysis to KRI for prior approval. 5.1.2 Steel structure materials (1) Indonesian standards to be followed for various steel structural materials shall be as stipulated in the relevant Indonesian standards to be followed for design and manufacture of EOT cranes.. (2) Constants used to calculate the steel materials of the crane structures are

as follows: - Longitudinal elastic modulus - Shear elastic modulus - Poisson's ratio - Coefficient of linear expansion - Specific gravity of steel

E = 21,000 kgf/mm2(206,000 N/mm2) G = 8,100 kgf/mm2 (79,000 N/mm2) l/m = 0.3 a = 0.000012  = 7.85 kg/dm3

5.1.3 Load affected to the traveling girder by crane There are inertia force and braking force generated by traveling, traverse moving, and rotation of the crane and wind pressure by wind. Loads created by the traveling and traverse movement are as follows: (1) Load occurring in the running direction 15% of the wheel load being braked applies to the top of rail.

2-7

Chapter 2 Crane

(2) Load occurring perpendicular to the running direction

This is the horizontal force occurring perpendicular to the direction of travel according to the movement of the mobile load, and its size is 10% of the wheel load. 5.2 Mechanical equipment 5.2.1

General (1) Hoisting equipment This equipment is installed on top of the trolley frame and is composed of motor, reducer, brake, wire drum, wire rope, and hook. This device must be designed and fabricated so that load is evenly distributed to both girders. (2) Traveling system In general, this device is installed on the girder and saddle. The motor is then installed on both edges of the girder and drives the traveling wheels attached to the saddle through the reducing gear. The number of drive wheels shall be 1/4 or more of the total wheel. (3) Horizontal traveling system This system is installed on top of the trolley frame along with the hoisting device. Composed of motor, brake, and reducer, it transmits the motor running to the left and right wheels of the trolley to drive the trolley.

5.2.2 Mechanical parts Machine part materials shall be selected appropriately according to conditions applicable. Woods and other inflammable materials shall not be used. The maximum operating stress applied to mechanical elements of cranes shall not exceed the maximum tolerance of bending, tension-compression, shear and/or torsion. The maximum working stress shall be uniaxial, biaxial or combined stress or equivalent stress, which includes mechanical elements of the working load. The maximum working loads shall include dead load, maximum live load, and the acceleration and deceleration forces resulting from normal operation of the crane. (1) Hook 1) Hook shall be made of forged steel or rolled steel. 2) The acting line of the force applied to the hook shall be in alignment of the shank center line as passing through the center of curvature at the inside edge of the hook. Design is carried out with the assumption that there is no bending on the shank of the hook. The maximum stress on the inner surfaces of the curvature of the critical section 90 degrees from the direction of vertical load, and the maximum stress at the shank’s thread root section shall have a design factor value 0.3 times the yield stress. 3) The screw shall be of a round shape and the nut height shall be greater than screw diameter. (2) Wire drum

2-8

Chapter 2 Crane

1) The Wire drum shall run smooth and be equipped with a flange. The

groove depth shall be greater than the diameter of the hoisting rope by 0.375 times or more. The drum shall be designed in such a way that the hoisting rope is wound for 3 or more times at the lowest position of the hook at the drum. When the hook is at the uppermost position, the hoisting rope shall not overlapped. 2) In case of the 6 ×37 wire rope, the drum pitch diameter shall be longer than the diameter of the hoisting rope by 25 times or more, and the Groove pitch shall be longer than the diameter of the rope by 1.14 times, or longer than the minimum value among the rope diameter + 3.175mm. 3) Wire drum shall undergo process of static balancing after fabrication. 4) The angle of the fleet of the grooved drum shall be less than 1/14 of slant (4°). 5) If there are no grooves on the hoisting equipment drum, the fleet angle shall be less than 2°. (3) Rope 1) If the hoisting rope consists of more than 100 core wires, the hoisting rope shall be composed of wire carrying tensile strength greater than 150kg/mm2. 2) The value derived by dividing the rated load and the hook block weight into numbers of rope shall be less than 20% of the rope breaking strength. As for ropes used to hold molten metal, the value thus obtained as above shall not exceed 12.5% of the rope breaking strength. 3) If the conduct exposed to main power supply is located at the bottom of the runway rail, a safety device shall be provided to prevent contact between the hoisting rope and the lower sheave block. (4) Sheave and hook block 1) Sheave shall be made from rolled materials, forging or cast steel, with balls or roller bearings mounted to reduce friction. 2) Each sheave shall be lubricated by the grease line, and an appropriate safety device shall be installed to prevent damage. 3) The pitch diameter of the sheave shall be greater than the wire rope diameter by 30 times or more according to operation conditions, by 18 times in the case of equalizer sheave. 4) The fleet slant of the sheave shall not exceed the 1/12 of the slant (4°45′) . (5) Track wheels Wheels shall be made from thermal-treated cast steel or forged steel. 1) The horizontal traveling wheels shall carry straight tread which is wider by 11mm to 16mm than the width of the horizontal traveling rail head. 2) The traveling wheels carry a straight tread which is wider by 36mm that the rail head.

2-9

Chapter 2 Crane

3) The drive wheels shall be installed on the forced fit shaft with a key,

while the driven wheels shall be self fit or fitted according to the manufacturer standards. 4) The driving as well as the free wheels shall be provided with similar dimensional axles from view point of replacements and spares. Machining of the axles / shafts shall be carried out such that tool cuts are avoided. (6) Rails 1) The rail specifications shall be decided by the crane speed, weight, and operation conditions. 2) The horizontal traveling rail joins shall be welded or connected with standard connectors. 3) Clearance between traveling rails shall not exceed 3mm, and the connector deviations shall be less than 0.5mm in all directions. The both ends of the rail shall be machined with no part left open. (7) Buffers 1) The crane buffer shall carry sufficient energy absorbing capacity to brake crane and trolley when the electric power is shutoff while the crane is running or horizontal traveling at a speed of at least 40% of the rated speed. (8) Greasing 1) In general in regard to bearing greasing, the inside of the reducer shall be greased in splash type and centralized greasing by electric motor shall be used for drums, upper sheaves and wheels. In case of the hoisting bottom hook block and special bearing which cannot be centrally greased, grease feeding type shall be used. If necessary, a grease gun shall be used. On traveling wheels, an oiler system shall be installed. 2) The toothed wheels in the reducer shall be of an oil bath type. 5.2.3 Steel structures (1) Girders 1) Prior to designing bridges, welded box type girders shall be considered first. To reduce the weight of the bridge, other types may be used based on mutual discussion. 2) The maximum vertical deflection of the girder occurred by the rated load and the weight of trolley and hoisting device excluding the weight of the girder and the impact load shall be less than 1/1,000 of the girder span. The process crane girder shall not sink below the horizontal line when the rated load (50% of the rated load in case of a service crane) and the self-weight of the hoisting device is applied. The process crane and the service crane shall be distinguished according to the average load of the weight lifted. The process crane means that the average load of the lifted load is greater than

2-10

Chapter 2 Crane

the rated load by 1/2 or more, and the service crane means, less than 1/2 of the rated load. 3) The camber of the main girder shall be applied across the span in a parabolic form. 4) Girder shall be fabricated in one piece as much as possible. If it is necessary to divide the girder into a few for transporting purposes, friction connection or bearing connection shall be taken through the use of high-strength bolts. 5) The high-strength bolts shall be evenly spaced in thickness or less 12 times that of the thinnest part of the compress part. 6) This thickness of the member shall be 8mm or more in the case of the steel with tensile strength 40kg/mm2, or 6mm or over in the case of high-strength steel. 7) The crane rated load (in units of ton) shall be indicated on both sides of the crane girder for ready identification from the bottom side. 8) For hot part of equipment, heat proof plate shall be used to block heat at the bottom and on the side. (2) Saddle (End carriage) 1) An appropriate safety device shall be installed to prevent a fall when the vehicles, shaft or carriage is damaged. The wheel base, in case the crane span is large, must be 1/7 or more of the span. 2) Saddle shall be designed in such a way that wheels can be replaced easily. Pad is used when using a jack or wedge to replace the traveling wheels. 3) End carriages shall be fabricated from rolled steel sections or plates, or both in riveted or welds construction to form an open web box or a solid box with essential openings suitably reinforced. If more than two wheels are required, bogies shall be provided 4) The end carriage shall be amply strong to resist all stresses likely to be imposed on them under severe service conditions, including collision with other cranes or stops. 5) The end carriages shall be of sufficient width and their length shall be such that no other part of the crane shall be damaged in collision. 6) Unless otherwise specified the wheel base shall not be less than 1/5th of the span. On the end carriages with more than two wheels, the wheel base shall be taken as the distance between the centers of the outer wheels. 7) The end carriages shall be fitted with substantial safety devices to prevent the crane from falling of more than 25 mm in the event of breakages of a track wheel, bogie or axle. These safety devices shall not interfere with the removal of wheels. (3) Trolley frame

2-11

Chapter 2 Crane

1) Trolley frame shall be a welded structure of steel plates and sections. 2) Trolley frame shall be designed so that it will not fall even if the

pantograph is damaged. 3) Trolley arrangement shall be designed in such a way that maintenance and inspection are easily performed. 4) All mechanical equipment shall be attached to the surface of the machined section. Ships shall be used only at the bottom of the brake or motor reducers. 5) Trolley floor shall be covered except the open section of the rope or the magnet cable. 6) Deck plate shall meet the safety standards. 7) For the high-heat and flame occurring places, heat proof plate shall be used at the bottom for heat insulation. 8) Trolley frame shall be fabricated in one assembled unit within the scope of transport limitations. In case the frame is in two subassembled units, then the design shall be such that any unit of a mechanism mounted on one sub-assembly of the trolley shall not come over to the other sub-assembly or over the cover plates of the splice. Connection between the two parts of the trolley shall be by turned and fitted bolts or rivets. 9) Drum bearings and supports for upper sheaves shall be so located that the load on each of the trolley wheels shall be as nearly equal as possible. 10) The trolley frame shall be built of rolled sections and plates to form a rigid structure and shall be capable of withstanding all stresses developed in the working of the crane and shall afford maximum accessibility to mechanical and electrical parts on it. It shall be designed such that at the highest position of hook, there shall be a minimum clear distance of 700 mm between the lowest point of trolley obstruction and the highest point of bottom block. 11) The trolley shall be fitted with substantial safety devices to prevent the trolley from falling by more than 25 mm in the event of breakage of a track wheel, bogie or an axle. These safety devices shall not interfere with the removal of wheels. 12) The trolley shall be provided with jacking pads for wheel removal. The jacking pads shall be at a height of about 300 mm from the rail level and shall not interfere with the removal of wheels, but located as near to the wheels as possible. Rail sweeps shall be provided in a similar way as indicated for crane end-carriage. 13) The trolley frame should be so built that a clear head room of minimum 2000 mm is available over the top of trolley platform from the bottom-most obstruction of roof truss. (4) Walkways and stairs

2-12

Chapter 2 Crane

1) The landing and walkways, ladders, and stair shall be installed to

facilitate maintenance and inspection. 2) The landing and walkways, ladders, and stair shall be designed to satisfy the following conditions: In case the installing conditions are unique or special, the crane supplier shall discuss with KRI for the approval. ① Handrail - Height : 1,100 mm - Pipe size : 32A - Toe plate : Flat Bar 60×6 (Carbon Steel) ②

Stair - Stair tread width : Min. 500mm - Footing : Height Max. 300mm, Width Min. 100mm - Angle of flight : Max. 50° - Materials shall be of such type which prevents slip. ③ Walkway - Flooring minimum thickness : 4.5 mm - Materials : Checkered Plate, expanded metal or grating - Toe plate shall be installed on both sides with thickness at least 4.5mm and height of 60mm. - Walkway width Traveling part : Min. 500mm Horizontal traveling part : Min. 450mm - Ladders shall be provided at the following locations: a) Crane walkway to crane gantry. b) Crane walkway to wheel inspection platform where provided. c) Crane walkway to power collector inspection platform d) Trolley floor to crane walkway (5) Operation room 1) The operation room shall be built with structural steel and fireproof materials to protect all the steel structure and control equipment. The closed operation room shall be equipped with hinged doors, sliding hinged doors on 3 sides or drop windows, while the roof with water proof plate shall be inclined towards backside to prevent ingress of water. 2) All sides and the steel plate thickness shall be 3.2mm or more. The window shall be fabricated with tempered glass and installed from inside the room so that, in case the window falls off, it will drop inside the operation room. To prevent the window from falling and damaged, safety steel net shall be installed. An appropriate handle

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Chapter 2 Crane

and a stopper shall be installed so that the hands or feet of the worker will not be injured when handling the windows. 3) The operation floor shall be treated with anti-corrosive steel plate, and the floor can be widened by installing hand rail in a similar way as prescribed under the walkway design conditions. Appropriate insulating materials measuring 20mm thick shall be laid on inside the floor of the operation room. 4) Heating systems, ventilation systems and/or cooling systems shall be installed in the operation room. Appropriate switches shall be provided so that the systems can be switched off when not in use. 5) The operation room shall be designed to enable the operator to have a field of vision as wise as possible. The crane supplier shall submit a perspective drawing for prior approval. 6) Equipment inside the operation room shall be arranged as predesignated. If there is no specific designation, the supplier shall submit a layout plan for prior approval. 7) Air-conditioned cabins, shall be sealed and pressurized and the inside pressure shall be 2 to 3 mm water gauge. Double glazing shall be provided. Floor, ceiling and side walls shall be covered with thermal insulation material like glass wool of minimum 50 mm thick. The air-conditioners shall be placed as near as possible to the driver’s cabin leaving sufficient working space in front of the air-conditioners for servicing. Easy approach and replaceability shall be ensured for filters, condensers etc. 8) Cranes shall be operated from the seated position. The seat shall have a hinged base and shall be located such that the operator has a view of all working points from the seated position. However, the seat, shall offer no obstacle to the operator while seating or leaving. The seat shall be provided with limited vertical, backward and forward adjustments which can be locked in any position but not swivel relative to controls. 9) The emergency stop and reset device of the crane shall be of hand operated type. This shall be located in an easily accessible position in the cabin. 10) Fixed service lighting shall provide adequate illumination of the crane controls. A low voltage socket outlet shall also be installed in the cabin for using a hand lamp with flexible leads. 11) Cabin floor shall be covered with heat and electrically insulated carpet, of a material which can be easily cleaned. (6) Name plate A sign indicating the date of manufacture, rated load, supplier name, and safety sign shall be attached to the center and on both sides of the crane girder for easy identification from the ground.

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Chapter 2 Crane

(7) Load to be considered when designing structures 1) Load shall be calculated by the supplier except the following:

Wind load (Applicable only if the system is exposed to wind.) - Maximum operating wind load : 25 kg/m2 - Maximum static wind velocity : Refer to ISZ-1 Part 3 Engineering. - Other loads resulting from weather effects: Refer to ISZ-1 Part 3 Engineering. 2) A stress table showing loads, strength, and stress calculation shall be included in the approval documents. 5.3 Electrical equipment and instrumentation 5.3.1

Outline Design of electrical equipment of the crane including crane wiring design and selection of cable shall be in line with the requirements laid down in the relevant Indonesian standards to be followed for design and manufacture of the EOT cranes..

5.3.2

Power system (1) Voltage selection 1) Main circuit : AC 440V, 3-phase(Except for special cases, no highvoltage or DC motor shall be used.) 2) Control circuit : DC 110V/220V or AC 220V/110V, single-phase 3) DC magnetic brake circuit : DC 110V/220V 4) Dynamic brake circuit : To be decided by the manufacturer. 5) Auxiliary circuit : AC 440V/220V/110V, single-phase or 3-phase. However, a single-phased 3-wire type (neutral earthing) shall be used for lightings; and the earth potential of the circuit shall be 150V or less. (2) Voltage variance range : Shall be governed by the provisions of Paragraph 6.2.2, Chapter 7, ISZ-2.

5.3.3 Motor (1) Type : Totally enclosed induction motor for crane 1) Forced cooled (internal cooling) wound type motor 2) Fan cooled(external cooling) wound type induction motor 3) Dust proof, squirrel cage type induction motor (2) Insulation Type of insulation is decided based on class F and class B raise type operation duty, maximum ambient temperature during summer, and short-time radiated heat. (3) Rating

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Chapter 2 Crane

Shall be decided by the maker according to each motor’s operation duty. The duty is determined based on formal report materials or through discussion with official groups. 5.3.4 Control method (1) Control system Shall be decided after discussing with KRI according to the using conditions and equipment characteristics. (2) Motor control system 1) In principle, secondary resistance control system shall apply to all cranes. 2) Reactor control is applicable to large capacity cranes. 3) Inverter control or primary voltage control system may be applied. 5.3.5

Brake system Braking systems for crane are as follows: (1) Hoisting brake 1) Each independent hoisting system of the crane shall be equipped with at least 1 spring set magnet brake. The magnetic brake shall be installed at the outer edge of the motor pinion shaft. 2) The braking torque of each brake shall be at least 150% of the maximum hoisting motor torque at the point of braking. 3) Wire and steel cranes shall be equipped with emergency brake on the wire drum. (2) Horizontal traveling brake Trolley shall be equipped with either a thrustor brake or magnetic brake. The brake shall be installed on the trolley motor shaft, with sufficient capacity to prevent dragging. (3) Traveling brake 1) The brake shall carried sufficient heat capacity and braking torque to brake bridge with a distance (m) equivalent to 10% of the rated speed (m/min) when the equipment is traveling at a rated speed with the rated load. 2) Each bridge drive system shall be equipped with motor brake, footoperated hydraulic brake, or electrical adjustable torque service brake.

5.3.6

Traveling collector (1) Traveling trolley wire type 1) Rigid trolley bar shall be used for the equipment used frequently or having large capacity. i.e.) Steel making plant, stabbing and blooming mill, and billet mill 2) Grooved trolley bar shall be used for general purpose other than the above-stated type. 3) 3-phase 4-wire type shall be used as a principle. (Sequence of installation shall be referred Part-2 ISZ CH-07) 4) In case the trolley bar is long, a thermocouple extension wire shall be installed to prevent effects resulting from voltage drop.

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Chapter 2 Crane

(2) Traveling collector 1) Equipment shall be subject to prior approval of KRI. 2) Crane for heavy duty shall be equipped with 2 sets of traveling

collectors of 100% capacity. 5.3.7

Power supply pull-in switch box (1) Model : Metallic, closed dust-proof type (including locking device) (2) Earthing point : Crane girder power supply incoming point (3) Annex equipment : Grounding relay (for alarm)

5.3.8

Common protective panel (1) Type 1) For electrical service room provided with dust and heat proof devices and ventilation fan with a filter, steel frame open type shall be installed. 2) For crane girder, a metallic closed dust-proof type shall be installed. (2) Parts 1) #2 SW: Breaker and main electronic contactor branched between #1 and #2 SW 2) #2 SW : At load sides (including CT) integrated ammeter 3) 1 set of common protective system

5.3.9 Magnetic control panel (1) Type It shall be based on Paragraph 6.4.6, Chapter 7, ISZ-2. (2) Parts 1) Complete set of magnetic contact for motors, MCCB, relays, CT, etc. 2) Reversible magnetic contact shall be mechanically interlocked. If there is temperature difference between the thermal relays and motors, the thermal relays shall be of an automatic temperature compensating type. 5.3.10 DC power supply system (1) Applications : Dynamic braking, control power supply, and electromagnetic brake (2) Type : Stationary (3) Capacity and rating : To be decided by the manufacturer. (4) Voltage : DC 220V/110V 5.3.11 Auxiliary circuit power supply Auxiliary power supply shall be available at least for maintenance purpose. Power supply shall be branched from the primary power.

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Chapter 2 Crane

5.3.12 Traversing collectors (1) Type : Festoon type, cableveyor type, trolley bar type (2) Specifications 1) Cable : 2 RNCT captype cable or higher-quality shall be used. 2) Cable shall have spare cores. 3) Notice for curtain type ① When the cable hanger is pulled, the tensile strength shall not be applied directly to its cable. ② Appropriate measures shall be taken to prevent the hanger roller from coming off from the beam. ③ Cable shall not be wound in round form, but clamped in flat type. 4) Notice for cableveyor type The radius of the cableveyor shall be greater than the cable diameter by 20 times. 5) Captype cable shall be included in the materials to be supplied by the supplier. 5.3.13 Meter box (1) Type : Wall mounted type (2) Place of installation : Operation room (3) Parts : 1) Main circuit voltage meter and ammeter 2) Control circuit voltage meter 3) Dynamic brake ammeter 4) Lamp and buzzer for various signals and alarms 5) Earth control source displaying lamp 6) Hoisting magnet ammeter 7) Meter for measuring operating hours (Motors and others) 5.3.14 Reversible controller (1) Type : In principle, horizontal handle type, or vertical type or universal type shall be used as needed. (2) Specifications 1) 1 unit of motor controller shall, in principle, be installed for each of the main hoisting, auxiliary hoisting, traveling, and horizontal traveling system. 2) If necessary, coasting notch shall be used on motors equipped with magnetic brake in addition to the hoisting function. 3) A limit switch shall have interlock contactors attached. 5.3.15 Metal resistors (1) Type : Steel grid resistor (Temperature rise : below 350℃), ambient

2-18

Chapter 2 Crane

temperature : below 50℃ (2) Others 1) The resistor shall be inserted into the frame one at a time to facilitate maintenance and inspection. 2) Fences shall be installed on top and sides of the resistor to prevent impact to an extent that the radiated heat will not be reduced. 3) A terminal in the resistor shall be installed on the front side of the resistor to facilitate inspection. 5.3.16 Limit switch (1) Limit switch shall be of a dust proof type. (2) Limit switch types and applications are as follows: 1) Common top and bottom limit switch for hoisting : Screw type (Warm gear) 2) Emergency top limit switch for hoisting : Lever type and central type 3) Over speed prevention : Centrifugal type and electronic type 4) Traveling and horizontal traveling end : Lever type 5.3.17 Parts (1) Operation standby and emergency press button switch (2) Operation alarm bell, buzzer or siren, and foot switch (3) Crane boarding safety devices : Press button switch and a buzzer shall be installed so that repeated signal can be given to the person for boarding confirmation. (4) Operator working display lamp: At the bottom of the cab Red Lamp : Occupied Green Lamp : Empty (5) Overload preventive safety equipment In case an object weighing 1.1 times the rated load, hoisting operation will stop along with alarm buzzer, and all turning, horizontal traveling or traveling is deactivated. (6) Following items shall be installed if requested by KRI or under special situation: 1) Maintenance interphone : Each operation room, electricity room, both platforms, hoisting craft 2) Wireless phone : For communication with crane signal man on the ground Type : Interphone or press talk Ground : Helmet phone On crane : Wall-mounted type cone speaker, suspension type speakers, foot switch, transmitters and receivers 3) Collision-preventive equipment : Warning or stopping devices for approaching to both sides of cranes or to a building wall; and collision prevention between two cranes operating in the vicinity of the same building Type : Modulated warning light type

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Chapter 2 Crane

4) Portable telephones shall be installed in the control room and

operation room for mutual communications. As the crane operator uses his hands continuous during operation, the telephone must not be of a manually-operated type. 5) Fan and filter 6) Air conditioner 5.3.18 Hoisting magnet : Shall be governed by the following items and Paragraph 6.6.5, Chapter 7, ISZ-2. (1) During power outage, crane operators and ground workers shall be directed and warned via lamps. (2) Charging systems and batteries shall have sufficient capacity to perform lifting or lowering of the rated load. Even for the power outage, power shall be supplied for at least for 10 minutes so that emergency lowering within the rated load can be performed by the magnetic brake inching. (3) Cranes provided with the hoisting magnet shall carry charging systems with sufficient capacity, or power shutoff compensating devices capable of maintaining adsorption power for at least 10 minutes even for the power outage or in other emergency. (4) The durability of the hanging equipment shall be 2 or more times the adsorption power based on yield strength. (5) The test for the hoisting magnet adsorptive power shall be conducted based on power 2 or more times the rated load. 5.3.19 Crane wiring design (1) Cable Power supply circuit

Control circuit

Signal and lighting circuit

Large capacity or hot ambient crane

BN Cable PN Cable

BN Cable PN Cable

BN Cable, PN Cable or heat-resistant Vinyl Wire

Medium capacity or heavy duty crane

BN Cable PN Cable

BN Cable PN Cable

BN Cable or Vinyl Wire PN Cable

Medium capacity or light duty crane

BN Cable PN Cable or CV, CE Cable

BN Cable PN Cable or CV, CE Cable

BN Cable PN Cable or CV, CE Cable

Note : Vinyl cable shall be of a cold-resistant type.

(2) Cable laying 1) 1 circuit for each radiation type MCCB 2) Conduit tube laying and duct laying 3) Cranes used in hot places shall use heat-resistant cable, and the

conduit tube and flexible cable shall be adiabatic treated.

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Chapter 2 Crane

(3) Cable size 1) When crane is operated at full load, the voltage drop shall be 5% or less. 2) Control and main circuit : The main circuit shall be made of copper wire,

(4)

(5)

(6)

(7)

(8)

guaranteeing safety at 100% or more of the allowable current.(wire size shall be referred Part-2 ISZ CH-07) 3) Main circuit cable : Safety electric current shall be 100% or more of the primary and the secondary rated current. 4) Common cable : Safety electric current shall be 70% or more of the combined rated electric current. 5) Lighting cable : Copper wire.(wire size shall be referred Part-2 ISZ CH-07) Spare cable 1) 10% of the core for electric power (at least 2 cores) 2) 20% of the core for control (at least 2 cores) (Operation room - Electric room - Crab and common electricity room) Terminal 1) Steel tube terminal or pressure terminal (Lighting power supply, signal, and control circuit are excluded from.) 2) Cable terminal identification numbers (A numbering tube is used.) shall be marked at the end of the cable. 3) Polarity color shall be marked at the end of the external cable according to IEC or equivalent standards. 4) Cable connected to the terminal shall be properly fixed so that they will not become loose by vibration. Conduit tube 1) Flexible conduit tube shall be used on a small radium or on a moving part. The length, however, shall be less than 500mm as a general rule. 2) Hook bolts shall be used to support the conduit tube. 3) The thickness of the large size outgoing line box, except the standard type, shall be greater than 2.0mm of steel plate. Steel duct 1) The space factor shall be 20% or less of the installation space. 2) The duct exposed to external radiant heat or flame shall be constructed in double duct, and shall be insulated with rockwool. 3) Ducts for the main circuit, control circuit, signal circuit, and lighting circuit shall be installed separately. Under an unavoidable situation, a dividing steel wall shall be installed inside the duct. 4) The curved section of the duct shall have a sufficient radius of curvature. In case an appropriate angle can be disregarded due to the characteristics of the crane structure, the duct shall be protected with rubber sheet, or wood cleat to avoid excessive stress with the cable. Grounding 1) All circuits inside the crane and the low-voltage equipment shall be grounded to the crane.

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Chapter 2 Crane

2) As in the case of high-voltage equipment, the traveling trolley cable

shall be grounded independently. (9) Lighting 1) The crane’s ceiling light shall be of a vibration-proof mercury discharged lamp, and the number of light and the intensity of luminosity shall be adjusted to 150 lux or more. 2) The lighting inside the operation room and the electricity room shall be of vibration-proof discharged lamps. 3) Lighting stand shall be installed in a place adjacent to both sides of the platform and the top of the crane. 6.0 Fabrication and inspection standards 6.1 Field test at supplier manufacturing plant The crane supplier shall conduct the following tests and inspections, and submit results according to the inspection standards of Crane issued by KRI. - Material inspection (including hardness) - Non-destructive inspection - Electric inspection - Dimensional inspection - No-load test 6.2 Crane manufacturing tolerance 6.2.1

Span Tolerance shall be decided as follows according to the crane span: (1) Span < 40m : ±6.0 mm (2) 40m ≤ Span : ±7.5 mm

6.2.2

Diagonal on wheels

: ±5.0 mm

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Chapter 2 Crane

6.2.3

Head Shall be greater than the prescribed dimension.

6.2.4

Trolley gauge A tolerance of ±3mm shall be allowed in the specified dimension. 6.2.5 In case the top of rail is flat, the inclination of the wheel axle from the horizontal direction shall be between +0.1% and +0.0%. (Refer to Figure 1.)

수평기준기 Leveler

Saddle

Inside 내측 :+0.1%

External side 외측 :+0%

Wheel axle 차륜 축

그림 1 Figure 1

6.2.6 The tolerance of the center of the trolley rail shall not exceed 0.15% of the trolley span, and shall be a maximum of ±4.0mm. (Refer to Figure 2.)

Trolley Span×0.15% Maximum ±4.0 mm

그림 2 2 Figure

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Chapter 2 Crane

6.2.7

The left and right horizontal deviation perpendicular to the direction of trolley traveling shall not exceed 0.15% of the trolley span, shall be a maximum of 5mm. (Refer to Figure 3.) Trolley Span(S) Horizontal 수평 line

d 수평 Horizontal line

Max 5 mm) d≤ 0.0015×S (최대

그림 33 Figure

6.2.8 Trolley rail shall be in level of the rail direction as for the rail surface, and the maximum unevenness shall be less than ±5 mm of the contact surface. (Refer to Figure 4.) Gauge B

●

●

C

A

●

●

D

그림 Figure 44

6.2.9 The center of the trolley rail shall be within 40% of the girder web thickness from the center line of the girder web. (Refer to Figure 5.)

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Chapter 2 Crane

6.2.10 Trolley rail straightness The center line of the trolley rail shall be within ±0.2% of trolley span, up to ±5mm, from the theoretical central axis of the rail. (Refer to Figure 6.). The rail joints shall not protrude. Rail center line

Figure 5

Web center line

Figure 5

Rail center line

Figure 5

±0.2% of span Figure 5 Maximum ±5mm

Figure 5

Web thickness

Figure 5

Figure 5

Figure 6

6.2.11 The center axis of the wheel shall be perpendicular to the rail center line as much as possible, and the difference between the maximum distance A and the minimum distance B shall be less than D/1000. (Refer to Figure 7.)

Rail center line

Figure 7

6.2.12 The center line of the trolley rail shall be facing each other, and if the wheels are installed on bogie, the vertical difference between the left and right of the trolley bogie pin shall be less than 0.15% of the trolley center distance, up to 2mm. (Refer to Figure 8.)

2-25

Wheel Span

c

Max 2mm) 0.15%(Max

Chapter 2 Crane

Wheel center axle

Wheel center axle

Trolley Span

Figure 8 .

Wheel center

Wheel base

±1mm

±1mm

Rail center axle

Wheel center

6.2.13 The center of the direction of the wheel running on the same rail shall be less than ±1mm from the rail center.

Figure 9 If the wheels have bushes, the above tolerance shall be calculated based on the central point between the both sides of the wheel boss. 6.2.14 If horizontal guide rollers are used, the rail center between the guide rollers at one corner shall not exceed ±1mm. (Refer to Figure 10.)

2-26

Center of distance

±1mm

Figure 10

between guide rollers

between guide rollers

Distance between guide rollers

±1mm

Rail center axle

Center of distance

Chapter 2 Crane

6.2.15 Other crane fabrication tolerances shall be governed by the provisions of KRI’s crane inspection standards. 6.3 Building run way girder tolerance 6.3.1

Span Tolerance shall be decided as follows according to the crane span. (Refer to Figure 11.) (However, the 4-point horizontal deviation within the contact surface of the crane running wheels shall be less 3mm.) (1) Span < 40m : ±6.0 mm : ±7.5 mm (2) 40m ≤ Span

6.3.2

The horizontal deviation between the left and right rail shall not exceed 1/3000 of the crane span. (However, the span shall be within the tolerance.) (Refer to Figure 11.) Wheel Span

Horizontal deviation  1/3000 x Span

Figure 11

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Chapter 2 Crane

6.3.3

The vertical bending shall not exceed 5mm against 10M. (Refer to Figure 12.) Top of existing rail

Within 5mm

Top of base rail

Figure 12

The horizontal bending shall not exceed 4mm against 10M. (Refer to Figure 13.)

Center of base rail

Within 4mm Center of existing rail

Figure 13

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Traveling wheel span

6.3.4

Chapter 2 Crane

6.3.5 All grade with the crane traveling range shall not exceed 1/2000. (Refer to Figure 14.) Center of existing rail

Within 1/2000 grade

Center of base rail

Crane traveling range

Figure 14 6.3.6

Tolerance for the traveling rail joint shall be less than 0.5mm at the top and bottom, and left and right, respectively; and the joint clearance shall not exceed 3mm.

6.3.7

The gap between the runway girder joint and the rail joint shall be greater than 1m.

6.4 Overall test 6.4.1 Load and operation test (1) The load for crane load test shall be 1.1 times greater than the rated load for initial completion test (including relocation test). (2) Deflection measurement of the girder shall be carried out as described in Paragraph (1) Girder of 5.2.3. (3) There shall be no cracks, distortions or damage to the handing tools and their foundations after load and operation tests. (4) During operation test, the crane shall satisfy the following items when traveling at a specific speed, hanging the load stipulated in Paragraph (1): 1) Operations including hoisting, horizontal traveling, traveling, and turning shall be smooth. 2) Protective equipment shall satisfactorily operate within the selected range. 3) Brake shall work in proper condition without creating any abnormal vibration. 6.4.2 Rated load test for each notch under the prescribed voltage (1) Speed 1) Hoisting The prescribed hoisting speed tolerance shall be +10% ~ -5%.

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Chapter 2 Crane

2) Lowering

The prescribed lowering speed tolerance shall be +25% ~ -5%. 3) Horizontal traveling and traveling The prescribed speed tolerance shall be +10% ~ -5%. 6.4.3 Motor electric current Shall be within the prescribed current level. 6.4.4

Vibration and noise There shall be no vibration, noise and/or other environmental problems that might adversely affect operators.

6.4.5

Insulation resistance The insulation resistance between wirings and ground shall be greater than 0.5 MΩ.

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Chapter 3 Belt Conveyor

Chapter 3 Belt Conveyor

3-1

Chapter 3 Belt Conveyor

Table of Contents 1.0 General ........................................................................................................... 3 1.1 Scope of application ........................................................................... 3 1.2 Scope of supply ..................................................................................... 3 1.3 Drawings and documents .................................................................... 4 2.0 Design conditions ........................................................................................ 3 2.1 General .................................................................................................... 3 2.2 Design standards and regulations ..................................................... 4 3.0 Engineering services and Supervision ..................................................... 4 3.1 Engineering services ............................................................................. 4 3.2 Supervision............................................................................................. 4 4.0 Painting · coloring · packing ..................................................................... 5 5.0 Design criteria ............................................................................................... 5 5.1 Mechanical equipment ......................................................................... 5 5.2 Steel structures ....................................................................................... 14 5.3 Electrical equipment and instrumentation ...................................... 17 6.0 Fabrication and inspection standards ...................................................... 20 6.1 Mechanical equipment ......................................................................... 20 6.2 Steel structures ....................................................................................... 21 6.3 Electrical equipment and instrumentation ...................................... 21

3-2

Chapter 3 Belt Conveyor

1.0 General 1.1 Scope of application This standard is applicable to the general technical specifications used to purchase equipment for belt conveyors--transporting equipment generally used to convey raw materials at steel mills. 1.2 Scope of supply 1.2.1

Range of supply (1) Supply conditions and range shall be governed by the provisions of the purchase technical specifications or requirements provided by KRI. (2) Unless specifically provided for separately regarding the range of supply, Part 2 Estimation, ISZ-2 shall be applied in common. General range of supply is as follows: 1) Belt conveyor design, manufacture, inspection, and transporting ① Steel structures Head tower, girder frame, trestle, stringer, take up structure, chute, skirt, belt cover, etc. ② Equipment and devices Drive unit, pulley & bearing, idler & stand, cleaner, movable chute, 2-way damper, tripper & shuttle, etc. ③ Electrical systems and instrumentation - Power & control cable and panel - Sensors such as pull cord switch, belt sway switch, and belt slip detector 2) Engineering and Supervision services for installation and operation 3) Submission of drawings and documents 4) Performance guarantee and warranty

1.3 Drawings and documents General matters pertaining to the submission of drawings and documents shall be governed by the provisions of Part 2 Estimation, ISZ-2. 2.0

Design conditions 2.1 General Design conditions shall be governed by weather and geographical conditions of the area where equipment is installed. Design conditions covering Cilegon area shall be governed by the provisions of Part 4 Design conditions, ISZ-2.

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Chapter 3 Belt Conveyor

2.2 Design standards and regulations 2.2.1 CEMA, ISO & JIS Standards and industrial standards of other countries may be applied, however, KRI’s prior approval is required in relation to the use of such standards. 3.0 Engineering services and supervision 3.1 Engineering services General common matters shall be governed by the provisions of Part 3 Engineering, ISZ-2. Detailed range of application is as follows: 3.1.1

Basic design (BD) Designs used to decide specifications and drawings forming the basis of the equipment purchase, detail design, and shop drawings based on the basic plan include the following: (1) Basic engineering 1) Material engineering plan

Required yard area, operation rate, transportation plan for each line, etc. 2) Examination of material balance, utility, and electric power requirements 3) Preparation of material flow diagram, and P & ID (2) Basic design (BD) Belt conveyor specification - Carrying capacity, belt speed, belt width, conveyor profile, drive system specifications, etc. 3.1.2 Detail design(DD) (1) Detail design shall be prepared based on the results of basic design for application at the plant or at site. (2) Construction drawings shall be prepared for field work. (3) List of materials for each equipment and bills of materials 3.2 Supervision 3.2.1

The supplier shall provide supervisory work to install the supplied materials at site. (1) Technical description and advice related to installation works (2) Provision of guidance and advice with respect to transporting and

3-4

Chapter 3 Belt Conveyor

unloading 3.2.2

The supplier shall attend the commissioning after the completion of installation based on the commissioning plan approved by KRI to provide required guidance and advice. If necessary, the supplier shall conduct trainings for KRI staffs on operation, maintenances, and other works.

4.0 Painting · coloring · packing Shall be governed by the provisions of Part 5 Painting · coloring · packing, ISZ-2. 5.0 Design criteria This design criteria shall applied when preparing the basic and detail design in accordance with Paragraph 2.2 Design standards and regulations. 5.1 Mechanical equipment 5.1.1 Calculation of transporting capacity The transporting capacity shall be calculated and designed based on the maximum load as sometimes trucks may be slightly overloaded due to transporting circumstances. Maximum theoretical load : Qm = 60  A  V  G Qm : Maximum theoretical load (ton/h) A : Loaded sectional area (m2) V : Belt speed (m/min) G : Apparent specific gravity of cargo (ton/m3) The maximum load shall be calculated taking into account the load carried during normal conditions to which the common overload rate of 1.1 ~ 1.3 times of the load is added. This data shall be used as reference when deciding the belt width, speed and drive unit. 5.1.2 Drive system (1) Configuration Belt conveyor drive system is composed of motors, reducers, couplings, drive pulley and brake or back stop, if necessary. (2) Drive motor 1) Motor power shall be calculated based on guidelines given in Indonesia CEMA/ISO standard code. The friction factor for idlers shall be taken as 0.03 considering Indonesian conditions and installation.

3-5

Chapter 3 Belt Conveyor

Pm =kP P = P1 + P2 ± P3 = 0.06  f  W  V (L + Lo)/367 + f  Qt (L+Lo)/367 ± h  Qt/367 Where, Pm : Installation motor power (kW) k : Safety factor for machine efficiency P : Required power (kW) P1 : No-load power (kW) P2 : Horizontal load power (kW) P3 : Lifting load power (kW) : Descending belt conveyor shall carry negative value. f : Roller’s rotational friction factor Lo : Adjusted horizontal conveying distance (m) W : Equivalent weight of moving parts of the conveyor excluding the conveyed load (kg/m) V : Belt speed (m/min)

Design value of f and Lo Equipment’s structural features

f

Lo

In case the status of installation is unsatisfactory

0.03

49

* In case the status of installation is satisfactory

0.022

66

In case the brake force of the downward conveyor is calculated

0.012

156

L : Belt conveyor horizontal length (m) Horizontal length between centers from the head pulley to tail pulley Qt : Maximum conveying capacity (ton/hr) h : Lift (m) The vertical height of lifting or lowering: The upward height of a tripper is included in case the tripper is installed. 2) The additional following elements shall be considered when calculating the belt tension and required power: ① Friction resistance of the driven pulley including the tripper pulley ② Resistance of the tripper driven by the belt ③ Frictional resistance between the skirt board and the cargo ④ Resistance resulting from the tilt of a roller ⑤ Inertial resistance occurring when the speed of cargo is

3-6

Chapter 3 Belt Conveyor

accelerated. ⑥ Conveyor belt or pulley’s cleaning system friction resistance ⑦ Take up device 3) Unless specifically requested by KRI, supplier’s motor specifications shall be as follows; however, such specifications shall be subject to prior approval of by KRI before signing a contract. ① In general, 3-phase induction motors shall be used; however, wound-rotor type motors may be used according to the load characteristics and the motor capacity. ② The demarcation line for use of low and high voltage motors shall be 180 KW - 200 KW as prevailing in Indonesian Industrial practices.. ③ The insulation shall be class F with temperature rise limited to class B. Protection clas shall be IP 54/IP 55 as per the installation conditions and surrounding atmosphere. (3) Couplings 1) Steel flexible couplings shall be used. If the motor power exceeds 40Kw, the fluid couplings shall be used to protect the drive system from overload. 2) Coupling specifications shall specify capacity which is 1.5 times or more of the required torque. (4) Reducers (1) For effective use of operation and maintenance space, parallel or right angle typed reducers are used in general. (2) The design power of the reducers shall be 1.5 times or more of the required torque. (3) The system shall use ball bearings with operating life-time exceeding 50,000 hours. (5) Brakes and back stops 1) Brake shall be selected taking into account the equipment layout and the belt stopping time to prevent materials being carried from overflowing due to the inertia of the conveyor belt when stopped. 2) Unless there are specific specifications, thrustor brakes shall be used. The brake may be designed in such a way that it can be installed on the brake wheel attaching couplings or installed by mounting a drum on an input axis of the reducer. 3) Brake specifications shall be chosen with due regards not to incur belt slip due to rapid change of tension when the belt comes to a halt. 4) Back stop is installed to prevent reverse movement of the belt when the belt conveyor, while ascending, comes to a halt. 5) If the reversing force is half or more than the frictional force, hold back shall be provided. Reversing power (Pb) = P3 - 0.7 ( P1 + P2)

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Chapter 3 Belt Conveyor

P1 : No-load power (Kw) P2 : Horizontal load power (Kw) P3 : Lifting load power (Kw) 6) If a brake is installed and if the brake torque exceeds the required reverse torque, the brake may be used in placed of the back stop. 7) The back stop shall be designed for installation on the drive pulley shaft opposite to the drive system. If necessary, the back stop may be designed in a reducer-mounted type in consideration of the maintenance space and the layout of the drive system. (6) Pulley 1) Selecting pulley ① Pulley can be classified into drive, head, tail, take-up, snub, and bend pulley according to the location of its installation and use; and is composed of cylindrical shell and welded part of shaft. ② The twisting stress resulting from the drive power and the bending stress resulting from the belt tension shall take into consideration when designing pulley. In case of the driven pulley, bending stress resulting from the belt tension shall be considered to maintain enough strength and stiffness. ③ To prevent belt slip, the coefficient of friction between the pulley shell and the belt shall be increased; and, to protect the shell, rubber lagging is used in general. ④ For pulley layout plan, refer to Figure 1. 2) Pulley standards face ① The minimum pulley face width is as shown on the following Table 5.1. However, the chute width and surrounding circumstances shall be considered in case of revamping works. Table 5.1 Minimum Pulley Face Width (Refer Indonesia standard code) Belt width

650 or under

800 ~ 1000

Greater than 1000

Pulley face width(mm)

Belt width+100

Belt width+150

Belt width+200

②

While it is economical to maintain less diameter of the belt pulley, it is more economical to maintain lager diameter in respect to belt operation and life span. Hence, the pulley diameter must be selected after examining the number of ply in a belt carcass and the elongation and compression of the top and bottom rubber on the pulley.

3-8

Chapter 3 Belt Conveyor

③

Body

The minimum pulley diameter shall be decided by specifications of the selected belt. The minimum pulley diameter based on the belt specifications are as shown on the following Table 5.2:

Table 5.2 Minimum Drive Pulley Diameter (Multiply ply fabric belt) Ply 3P 4P 5P 6P 7P 8P

NN-100

300

400

500

600

700

800

NN-120

300

400

500

600

700

800

NN-150

350

450

550

650

750

850

NN-200

400

500

600

750

850

1000

NN-250

400

550

700

800

950

1100

NN-300

450

600

750

900

1050

1200

Note) The diameter of the pulley corresponding to the tension of the tail and take up shall be 80% of the diameters shown above; that of the pulley corresponding to the tension of the snub and bend shall be 60% of the diameters shown above.

Table 5.3 Minimum Pulley Diameter (Steel cord belt)

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Chapter 3 Belt Conveyor

Pulley Diameter for Allowable Stress (mm) ST-No.

90% or more

70% or more

50% or more

30% or more

Less than 30%

800

650

600

450

350

300

1000

850

750

600

450

450

1250

950

850

700

500

500

1600

950

850

700

500

500

2000

1200

1100

850

600

550

2500

1350

1200

950

700

600

3000

1500

1300

1050

750

650

Note) In respect to the pulley diameter, the head and drive pulley shall use 70% or more of the tension and allowable stress, while the tail pulley uses 50% or more. The diameter of the other bend pulleys shall be selected considering the related tension.

④

The distance between the pulley bearing axis shall be designed as short as possible to maintain optimal strength and stiffness, considering the selected pulley width and the chute width. 3) Pulley lagging ① Lagging is provided to increase the efficient of friction between the belt and the drive pulley; to reduce wear on the pulley face, and to provide self-cleaning effect. In general, the lagging thickness shall be 12mm or more for the drive pulley, and at least 6 mm, for the driven pulley. ② Lagging is grooved in a herringbone type(Figure 5.1) or a diamond type(Figure 5.2) in most cases; however, the diamond type laggings shall be used unless there is a special requirement. ③ The herringbone type shall not be used on the reversible conveyor. For details on the size of lagging grooves, refer to Table 5.4.

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Chapter 3 Belt Conveyor

Figure 5.1 Herringbone Type

Detailed Sizes of Lagging Groove S

D

W

t

T

Table 5.3

Figure 5.2 Diamond Type

T: Thickness T : Thickness S: Space S : Space D: Depth D : Depth

W: Open width W : Open width t: Bottom thickness t : Bottom thickness

3-11

Chapter 3 Belt Conveyor

Groove Sizes

Light duty

T

W

D

S

12

8

7

28

Lagging Hardness

Attaching Method

Shore hardness Drive pulley

Medium duty

12

8

7

Vulcanized lagging

34 55~65

Heavy duty

12

Driven pulley

8

7

40

Plain lagging

From 35 to 45

Same as above

4) Others ① If no key is used, the pulley boss and the shaft shall be

②

③

④

⑤

assembled in the tight fit method, or in the transition fit method, if a key is used. The pulley boss shall be annealed after welded and then welded to the shell. The welded part of the shell and the boss shall be inspected by an ultrasonic tester. The pulley bearing shall use automatic aligning roller bearing. The bearing shall be designed to carrying operating life span longer than 50,000 hours. Diameter of pulley shall be conservatively sized to ensure torque transmission, non-separation of belt plies and adequate belt life. Stress in belt carcass shall be below fatigue limit of rubber bond between plies. Standard diameter as per Indonesia (CEMA/ISO) standard code shall only be considered. Materials to be used for pulley shall be follows: Pulley shell A 570 Gr. 40 Pulley rim Hub

-

Mild steel, SNI: ( ) Mild steel, SNI: ( ) A 709 Gr. 50 Cast steel, Gr. Ⅱ, SNI: ( ) A 709 Gr.

50 or fabricated from forged steel, SNI: ( )

3-12

Chapter 3 Belt Conveyor

Shaft

Class-Ⅳ, SNI: ( ) up to 150 mm 40cr 1MO 28 AISI 4142, SNI: ( ) above

150 mm dia ⑥ Pulley face width and dimensional tolerances for the pulley shall be as per Indonesia standard code. (4) Idlers 1) Idlers selection ① The idlers support belts and carried materials while revolving.

In general, the idlers are composed of a stand consisting of a steel frame which supports rollers and that made of common structural carbon steel tube. Standard sizes of idlers are shown on the attached Figure 5. ② Elements seriously affecting the drive horsepower, such as roll diameter, bearing specifications, and seal arrangement, shall be carefully chosen to reduce frictional resistance. ③ Types and arrangements of the idlers shall be designed as shown on Table 5.5 and the attached Figure 1 to minimize a fall of materials being carried to conveyors. Unless otherwise specifically provided for, labyrinth seal shall be used to protect the bearing from dust and moisture, and to maintain optimal lubrication status. ④ Rollers used to carry bolus coke shall be designed in consideration of anti-abrasion by applying rubber coating, if requested by KRI ⑤ Out of roundness of the roll shall be 1.6 mm for idler length below 1350 mm and 2 mm for idler length of 1350 m and above. ⑥ The rollers for the idlers shall be made of seamless tube or ERW pipes of shell thickness not less than 4.5 mm. Spindle shall be made of carbon steel C-45 of =>Indonesia standard code. Roller bearing housing shall be of pressed steel. Idler frame shall be fabricated from rolled steel sections. ⑦ Roller and spindle diameters of idlers shall be selected based on the guidelines stipulated in Indonesia standard code CEMA/ISO. Fixing centers of the idlers shall conform to Indonesia standard code CEMA/ISO. The construction of idlers shall be such that the co-efficient of rolling resistance of the roller and the grease seal is minimum. 2) Trough carrying idlers ① The standard type is composed of a three-in-line roll carrying the same length, and the rake angle of both rolls of the troughing idlers shall be 20 to 30 . ② To prevent meandering of the belt, the carrying idler shall be tilted by approximately 1 ~ 2 in the direction of the belt moving; however, no inclination shall be made in the forward and backward direction line. 3) Return idlers ① The return idlers are horizontal roll installed between the brackets mounted at the bottom of the support structure equipped with the carrying idler, and support the belt returning after carrying materials.

3-13

Chapter 3 Belt Conveyor

②

In addition to supporting the return belt, the return idlers may be used to adjust the installation location of the return belt or to drop the materials attached to the belt face. ③ To prevent damage to the curved section of the conveyor frame or the belt, an inverted V-type return idler may be installed. 4) Self-aligning idlers ① The self-aligning idlers are installed to prevent meandering of

5)

6)

7)

8)

belt, and the applicable types shall be varied according to the forward or reverse direction of the belt. ② Common type of the stand shall be of a pivot type, and the self-aligning idlers shall be installed at intervals based on Table 5.5 according to the belt width and types of carried materials. Impact idlers The impact idlers are used to prevent damage to the roller and belt by absorbing impact when the carried materials fall. The impact idlers must be used especially when the materials being carried are of large and heavy. Transition idlers The transition troughing idlers are controlled within the range of trough angle 5 ~25, and shall be installed in such a way that the belt can take the form of a trough between the common troughing idler and the adjacent pulley. Spiral return idlers These idlers are the oblique type rubber disc or a return idler covered with rubber. The spiral return idler removes materials attached to the belt and minimizes the belt meandering by the rubber winding shape. Idler spacing Unless specifically provided for, the standard idler spacing shall be decided based on the following conditions. For standard spacing of the idler variable according to belt width and types of carried materials, refer to Table 5.5 General idler spacing. ① Belt weight and specifications ② Carried materials weight ③ Idler rating ④ Belt tension ⑤ Belt deflection (Maximum tolerance: 1% of roller spacing) ⑥ Idler operating life (Bearing operating lifetime: At least 30,000 hours) ⑦ Loading points exposed to impact

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Chapter 3 Belt Conveyor

Belt width (mm) 600or under 750 900 1,050 1,200 1,400 1,600 1,800 2,000 2,200 or over

Table 5.4 General Idler Spacing Troughing Carrying Idler Impact 3 Material Weight(ton/m ) Return Idler Idler at Loading 0.4~0.8 1.0~1.5 1.6~3.2 Points 1,370 1,220 1,220 3,000 360 1,370 1,220 1,220 3,000 360 1,370 1,220 1,070 3,000 360 1,370 1,070 1,070 3,000 360 1,220 1,070 1,070 3,000 360 1,220 1,070 920 3,000 360 1,070 920 920 2,500 360 1,070 920 800 2,500 420 1,070 920 800 2,500 420 1,070 800 800 2,500 420

Self-aligning Idler Carrying Side

Return Side

1 set per 30m

1 set per 30m

Detail design may vary slightly according to design conditions. (5) Belts 1) Belt specifications shall be selected based on the maximum tension of the belt, and the belt strength shall be selected based on the belt strength calculated in the following formula: Belt strength: Td (kg/cm) = Maximum belt tension(kg)  safety factor(S.F) / Belt width(cm) 2) Safety factor(S.F) shall be applied as follows based on the selected belt specifications: NN belt (Fabric) : 12 or more ST belt (Steel cord) : 7 or more 3) Belt elongation is related to the selection of take up stroke when equipment layout is planned, and shall apply as follows according to belt specifications. NN belt (Fabric) : 2% or more of belt length ST belt (Steel cord) : 0.3% or more of belt length

5.2 Steel structures

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Chapter 3 Belt Conveyor

5.2.1

General (1) The belt conveyor structure shall be designed to carry sufficient rigidity against distortion under any load and all conveyor structure except the yard line shall be designed in a girder type frame of a truss form. (2) Appropriate types of stairs and platforms shall be installed on the structure to gain easy access to the conveyor drive system for greasing and maintenance. (3) The structure shall be designed for bolting or welding and shall allow site installation and fabrication as much as possible.

5.2.2 Head tower (1) The size of the head tower floor shall be decided considering the maintenance space for chute and drive units. (2) To enable an appropriate maintenance for heavy materials, roof and/or hoist rail shall be designed on top of the tower, as needed. (3) If bolting is used, high-tensile bolts shall be used on major members such as columns and girders and common bolts for members like runners/purlins. 5.2.3

Girder frame and trestle (1) Standard trestle spacing shall be designed according to peripheral equipment and site situation. Also this should be guided from resonance check of the girders. (2) Design shall be as per Indonesia standard code/ relevant clauses in civil/architecture chapter. (3) The minimum height of the structure crossing the road shall be governed by the provisions of Paragraph 2.13.2, Chapter 11; or shall be 4.5m or higher in the case of maintenance road. (4) Fall preventive plates including the walkway shall be installed under the belt in the following places: 1) If a structure intersects the road (Applicable length: road width + 4,000mm) in total 2) If a structure is laid over other buildings, structures, and utility (5) Unless otherwise specifically instructed, the fall preventive plates shall be designed in black sheet. (6) Brackets, including cable trays, shall also be considered in the design. (U bolts for the pull cord S/W shall be installed at the plant, and sensors and brackets, at site.) (7) Unit structures that can be transported shall be delivered after the fabrication at the plant, and the girder frame walkways, assembled at site after being fabricated at the plant.

5.2.4 Tension control equipment (1) The traveling distance of the tension control equipment shall be designed taking into account the elongation of the belt. (2) Gravitational take up system shall be the standard equipment. If the

3-16

Chapter 3 Belt Conveyor

equipment is designed in a platform system due to equipment layout situation, safety factors shall be sufficiently considered prior to selecting wire ropes and designing the platform. (3) If the horizontal distance of the conveyor is less than 30m, a screw type may be used. (4) A safety fence and walkway shall be installed in the vicinity of the tension control equipment. 5.2.5 Chutes and skirts (1) Chute plate shall preferably be 4.5 mm to 6 mm thick and shall be designed in a flange split bolting type to facilitate maintenance. (2) The chute slope, in general, shall be designed to be 55° or more considering the characteristics of the materials carried, while slope angle for coal and iron powder shall be 60° or more. (Refer to attached Figure.2, 3, and 4.) (3) To prevent wear on the material contract surface, stone boxes or liners shall be taken into consideration when designing chute, including the materials discharge curves. (4) Deflectors shall be installed to balance eccentric loading when the materials drop due to changes in the amount of materials or the material itself. Deflectors shall be designed to enable the angle adjustment, minimizing abrasion caused by the materials by installing stone boxes or liners. (5) Materials other than coals shall be designed in a stone box type as much as possible when the chute is designed, making sure that the materials do not make direct contact with the front face of the chute. The stone box width shall be 300mm or more and the snub pulley shall be located inside the chute. (6) To prevent the dispersion of dust, a cover shall be installed on top of the chute and a rubber plate at the belt entrance. The chute cover shall have a door for inspection and shall be designed for an easy replacement. (7) The skirt shall be designed in a steel cotter to facilitate adjustment and replacement. However, bolts and nuts may be used instead of cotters where vibration is expected. (8) In general, the skirt width shall be designed to be 2/3 of the belt. In case size of the carried materials is consistent, the skirt width shall be at least 3 times that of the materials; or if the material size is irregular, the skirt width shall be more than 2 times that of the largest lump. (9) The skirt length generally is 1.5~2m; however, the length may be adjusted according to the condition of the materials carried and the arranged equipment. The skirt length shall be more than 3 times the skirt width if there is no dust collector hood installed; or more than 4 times if a dust collector hood is installed. (10) Except for coal, anti-abrasive liner shall be installed on the side of the skirt. 5.2.6 Belt covers

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Chapter 3 Belt Conveyor

(1) The belt covers shall be made of a corrugated sheet measuring 0.45mm

or more in thickness and an inspection door installed at each interval of 30m. (2) The belt cover shall be designed in a structure which facilitates opening/closing of the cover and shall be fastened using a wedge or a clamp to withstand any wind load. 5.2.7 Others (1) The conveyor walkway board shall have expanded metal thickness greater than 4.5mm and the checkered plate thickness greater than 4.5mm. (2) To prevent a fall of materials and to facilitate maintainability, the checkered plate shall be installed in places where the fall prevent plates and the take up bend pulley are installed. (3) This shall be without violating norm as specified in Indonesia standard code.. (4) The over bridge shall be installed at intervals of 300m to secure the inspection routes and if the height exceeds 2m, back bands shall also be installed. (5) In case a conveyor is installed high, vertical ladders or spiral stairs may be installed instead of inclined stairs. (6) Where greasing is required, 1/4” standard size grease nipples shall be installed, or the supplier’s standard specifications may be applied. (7) Unless specially instructed, safety covers shall be installed on the following equipment and near such equipment. 1) Rotators of drive systems, such as gears, chains, couplings or brakes. 2) All pulleys except those installed inside the chute. 3) Motors installed in places where fall of materials is expected. 4) Take up trucks (8) For the cleaning devices, 1 set of P type cleanser shall be installed on the head pulley and 1 set of P type scrapers, at the front of the take up bend pulleys and the tail pulleys. For the tripper head pulleys, 1 set of P type cleaner shall be installed.

5.3 Electrical equipment and instrumentation 5.3.1

General General conditions covering the electrical systems and instrument design conditions and engineering services shall be governed by the provisions of Chapter 7 Electrical systems.

3-18

Chapter 3 Belt Conveyor

5.3.2

Control equipment Unless otherwise specifically provided for, the control equipment specifications shall be selected based on the following. Detailed information on the place of installation and types shall be subject to confirmation by the owner. (1) High and low voltage panel: Dust proof type. (2) Monitoring and control panel, CRT based graphic operating station (3) Site control systems 1) Pull cord switch ① Applications : Emergency belt stop and interlock configuration ② Installation place : Left and right frame of the conveyor at an interval of 50m ③ Type : Outdoor dust-proof and waterproof, target type ④ Items to be considered during designing stage The switch is connected with the wire rope which penetrates through, and supported by the U bolts, the left and right frame of the conveyor. U bolts are installed with an interval of 2~3 m in general. For stringers, the switch is installed in one place for each support; or in one place for each vertical part at every other truss section in the case of the girder frame. 2) Belt sway switch ① Applications : To prevent belt meandering or to detect offset operation ② Place of installation : On top of the left and right frame of the conveyor ③ Type : Outdoor dust-proof and waterproof, touch roller type ④ Items to be considered during designing stage In general, this switch is installed in each left and right place in the vicinity of the head for a short-distance conveyor (length not exceeding 30m); or in 2 places on the left and right side of the head and tail (length exceeding 30m). Since the offset operation is detected when a touch roller is tilted as much as 35~55º, an inspection window not interfering with the belt cover or an opening hole on the belt cover shall be applied. 3) Belt speed switch (Belt slip detector) ① Applications : A slip used to detect an unbalance between traveling speed of the belt and elevator and the pulley rpm. ② Place of installation : Belt pulley frame ③ Type : Outdoor dust-proof and waterproof, proximity type ④ Items to be considered during designing stage There are a variety of type available, such as the non-contact type, horizontal type and low-speed types. Unless otherwise specifically provided for, the non-contact, proximity type shall be used. As brackets and/or sensor accessories may be omitted, prior check is necessary to check items such as the sensing piece tap installed at the edge of the pulley shaft. 4) Chute switch ① Applications : To check materials stuck inside the chute

3-19

Chapter 3 Belt Conveyor

②

5)

6)

7)

8)

Place of installation : Shell plate at the center bottom of the chute ③ Type : Chain & steel bar, electrostatic capacity type ④ Items to be considered during designing stage This switch is installed in places where the conveyor operation rate is considered and the prevention of materials overflow is particularly required. It shall be a place where there is no collision occurring when materials fall. If necessary, separate covers may be installed near the chute switch to prevent the fall of materials. Tilt switch ① Applications : Installed on top of bin, this switch prevents overflow when materials are loaded in full. ② Place of installation : Top of storage like the bin ③ Type : Outdoor dust-proof and waterproof type ④ Items to be considered during the design stage This switch, in general, is installed along with the ultrasonic leveller. The switch shall be installed in places where there is no interference with the conveying equipment like the tripper and other related structures. Related specifications and the detection position which suits the storage capacity of the bin shall be selected. Ultrasonic leveller ① Applications : Installed on top of the bin and pond, this leveller detects when materials and fluid are filled in full level. ② Place of installation : On tope of storage equipment such as the bin ③ Type : Outdoor dust-proof and waterproof type ④ Items to be considered during the design stage This leveller detects when materials are filled in full inside the storage facility. Appropriate level and specifications shall be selected according to the facility shape plan of high, and low levels. The leveller shall be installed in places where there is no interference with the conveying equipment like the tripper and other related structures. Alarm horn ① Applications : Alarm prior to starting equipment and danger alarm ② Place of installation : Places within 50m from the conveyor head, or adjacent to the blower, pumps and other drive systems. ③ Type : Alarm and warning lamp type Metal piece detector ① Applications : Detects foreign matters such as metals contained in the materials being carried on conveyor. ② Place of installation : On top of a conveyor frame ③ Type : Outdoor dust-proof and waterproof type

3-20

Chapter 3 Belt Conveyor

④

Items to be considered during the design stage This detector is installed on top of the belt near the tail for conveyors which require detection of metals and other foreign matters due to the characteristics of operation. This is also installed along with a magnetic separator. The detector shall be installed appropriately to prevent interference with the belt cover and the carrying idler. 9) Magnetic separator ① Applications : Magnetically separates and discharges foreign matters such as metals contained in the materials being carried on conveyor. ② Place of installation : Conveyor Frame top ③ Type : Outdoor dust-proof and waterproof type and electro magnetic type ④ Items to be considered during the design stage As most magnetic separators are of suspended type which are installed above the conveyor belt, appropriate type of house shall be provided so that the separator can be installed, making sure that there is no hindrance to the passage through the conveyor walkway. A guide chute shall also be installed near the separator so that the foreign matters, after separated, can fall to the guide chute. 10) Proximity limit switch ① Applications : This switch detects the position of the stroke position when the moving equipment like the tripper or shuttle runs on rail, and is used simultaneously with the lever limit switch in most cases. ② Place of installation : At the bottom structure of the traveling rail (Stroke end part) ③ Type : Outdoor dust-proof and waterproof type 11) Lever limit switch ① Applications : This switch is installed at the end of a stroke to electrically turn off power to prevent over stroking when the moving equipment like a tripper or shuttle runs on rail. ② Place of installation : At the bottom structure of the traveling rail (Stroke end part) ③ Type : Outdoor dust-proof, and waterproof type 6.0 Fabrication and inspection standards 6.1 Mechanical equipment 6.1.1 This standard shall be prepared to satisfy Paragraph 5.0 Design criteria and

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Chapter 3 Belt Conveyor

performance. 6.1.2 The drive systems shall be delivered in the assembled status after completing an independent performance test. If overall fabrication of the drive system is needed due to the site situation, a prior discussion shall be held with KRI. 6.1.3 As for the pulley, carbon steel tube or a common type of rolled steel shall be used to suit design conditions. All welded part shall be annealed and foreign matters and/or rust removed totally from the drum. Then lagging shall be carried out after applying adhesives. In particular, the edge of the pulley shall be finished positively to prevent the peeling of lagging. 6.1.4 Unless otherwise specifically provided for, cast iron shall be used for the bearing housing, or cast steel in case the bearing housing requires highimpact resistance and rigidity. 6.1.5

Inspection standards covering mechanical systems shall be governed by the provisions of the KRI inspection standards.

6.2 Steel structures 6.2.1 Steel structures shall be fabricated according to the basic, detail design drawings and Paragraph 5.0 Design standards. 6.2.2 Units of the structure that can be transported shall be shop fabricated and assembled as much as possible prior to delivery. For equipment that shall be provisionally fabricated at the plant prior to delivery or those to be delivered in piece by piece shall require prior discussion with KRI. 6.2.3

For equipment which are likely to be transformed after fabrication, transporting and installation, appropriate tools (jig, etc.) or lifting lugs shall be provided to prevent such deformation or distortion, as needed.

6.2.4

In case of bolts and nuts which are fitting materials used to assemble equipment, spare items shall be provided in addition to the quantities shown on drawings.

6.2.5

The steel structure inspection standards shall be governed by the provisions of the KRI inspection standards:

6.3 Electrical equipment and instrumentation 6.3.1

The fabrication and inspection standards covering electrical systems and

3-22

Chapter 3 Belt Conveyor

instrumentation shall satisfy the provisions of Paragraph 5.3. 6.3.2

The fabrication and inspection standards covering electrical systems and instrumentation shall be governed by the provisions of the KRI inspection standards:

Fig. 1. Conveyor Model

Discharge chute Belt direction C

C

C

C

C

P

R

C

C C

HP

Feed chute

C

P

S

S

P

C

P

skirt

R

I

I

R

P

I

I

I

I

R

TP W

HP

: Head pulley

TP

: Tail pulley

P

: Pulley (Bend pulley, Snub pulley)

C

: Carrier idler

I

: Impact idler

R

: Return idler : V Type scraper for belt cleaning

W

: Take-up weight

3-23

P

Snub Pulley Cleaner 50kg Rail

300 or more

Chapter 3 Belt Conveyor

Internal liner plate 100 or more o

60 or more Skirt Rubber

(perpendicular Fig. 2. Head Chute Model (Tree type feeder) to belt)

Note: 1. The head chute shall be in a stone box type, or a controller attached deflector type. Spilled materials shall make a direct access to the opposite plate. In addition, the snub pulley shall be located inside the chute. 2. The angle of the chute shall be greater than 60˚. 3. The inside liner shall be installed as shown on the left drawing. 4. The distance between the snub pulley and chute shall be greater than 100mm. 5. The skirt rubber shall be installed perpendicular to the belt.

Snub Pulley Cleaner

Internal liner plate 100 or more

50kg Rail

300 or more

o

60 or more Skirt Rubber (perpendicular to belt) Pulley width +200 or more

Fig. 3. Head Chute Model (Parallel type feeder)

Note: 1. The chute width shall be larger than that of the pulley by more than 200mm. 2. The stone box shall be installed on both sides.

Width of pulley +200 or more

Pulley width +200 or more

Fig. 4. Inclined Chute Model

60

o

liner

300 or more

Note: 1. An anti-abrasion liner board shall be installed on the center of the sloped chute. 2. Angle of inclination shall be greater than 60˚.

200

60 300 or more

o

liner

3-24

Chapter 3 Belt Conveyor

Fig. 5 A. Carrying roller set B

a1 l1

a1

l1

1

a h1

H2

D1

D1

D1

l

g1

H1

a1

n1 s 1

1

S a1

over f

m

f1

e1

t1

t

1

H1 와 H 2 오차

S α

D₁

a1

ℓ1

h1

m1

n1

e1

f1

20。 ˚ 30。 ˚ Trough Trough

400

89.1 145

153

+2.4 - 0

125

640±1.6

140

185

185

450

89.1 165

173

+2.4 - 0

125

690±1.6

140

205

205

+2.4 - 0

125

750

900

1050

20˚ 。 89.1 210 114.3 265

114.3 315 30˚ 。 139.8 370

188

218

273

323

380

740±1.6 L 140

220

01

14.5 ±0.5

400

450

+2.4 - 0

140

+2.4 - 0

150

+2.4 - 0

150

+2.4 - 0

180

840±1.6

220

150

500

under 7

9.5 d1

600

89.1 180

Belt 폭

3mm under

D1

500

t1

적용 Bolt g₁

Belt width

Belt 폭

Applicable bolt g1

Belt width

Size 치 수

Error between H1 and H2

Unit: mm

250

250

600

b1

1040±2

c1

1190±2

l1 L1

160

c1

160

M12

305

315

355

365

750

900 4mm Under

1340±2

180 18.5 ±0.7

1200

139.8 420

430

+2.4 - 0

1400

165.2 500

510

+2.4 - 0

250

180

1490±2

1600

165.2 580

590

+2.4 - 0

250

1930±2.5 280

1800

165.2 650

660

+2.4 - 0

280

2220±2.5 330

2000

651.2 730

740

+2.4 - 0

280

2420±2.5

330

2200

651.2 800

810

+2.4 - 0

300

2620±2.5

330

22.9 14.5 ±0.7

25.5 ±0.7

3-25

430

1050

470

480

1200

555

570

12

180

1730±2.5 280

420

17

1400 Under 10

1600

635

650

705

720

785

800

2000

845

860

2200

5mm Under

M16

1800

Chapter 3 Belt Conveyor

B. Carrying roller

d1

D1

L01

b1 l1 L1

c1

c1

Unit: mm 치Size 수

Belt폭 Belt

Belt폭 Belt

width

400

D1

ℓ1

89.1

145

L1

L01 + 0 - 0.

153

C1

d1

b1

width

175

400

195

450

5 450

89.1

165

+ 0 - 0.

173 5

500

89.1

180

+ 0 - 0.

188

210

5 600

89.1

210

+ 0 - 0.

218

500 8.0 ±0.2

20

240

14.0 + 0 - 0.5

600

5 750

114.3

265

+ 0 - 0.

273

295

750

345

900

5 900

114.3

315

+ 0 - 0.

323 5

1050

139.8

370

+ 0 - 0.

380

410

1050

8 1200

139.8

420

+ 0 - 0.

430

25

18.0 + 0 - 0.5

460

1200

8 1400

165.2

500

+ 0 - 0.

510

540

1400

8 1600

165.2

580

+ 0 - 0.

590

620

11.2 ±0.2

30

22.4 + 0 - 0.5 1600

8 1800

165.2

650

+ 0 - 0.

660

690

8 2000

165.2

730

740

2200

165.2

800

810

1800 35

+ 0 - 0. 8 + 0

770 840

3-26

40

25.0 + 0 - 0.5

2000 2200

Chapter 3 Belt Conveyor

C. Return roller set C. Return Roller Set

g2

H1 D2

H2

n2

h2

l2 B

m2

2

f2

t

f 2 +a

h2

j

e2

폭 D2

ℓ2

m2

400

89.1

460

640±1.6

450

89.1

510

690±1.6

500

89.1

560

740±1.6

600

89.1

Roller 660D. Return 840±1.6

850

e2

f2

t2

j

적용

오차

Bolt

Belt 폭

g2

400 Under 3 60

110

14.5±0.5

9.5

Under 7

450

80

500 M12

600

L 02

1040±1.6

114.3

1080

1190±2

1050 119.8

1150

1340±2

1200 149.8

1300

1400±2

1400 165.2

1510

1730±2.5

750 900

d2

900

114.3

h2

100

130

18.5±0.7

12

D2

750

n2

H1 와 H 2

Belt width

수

Size

Applicable bolt g2

치

Belt

Error between H1 and H2

Belt width

Unit: mm

Under 4

1050 b2

22.9±0.7

c2

l2

14.5 L

Under 10

120

160

1400

c2

2

90

1600 165.2

1710

1930±2.5

1800 165.2

2000

2220±2.5

2000 165.2

2200

2450±2.5

2000

2200 165.2

2420

2620±2.5

2200

25.5±0.7

3-27

17

Under 5

1200

M16

1600 1800

Chapter 3 Belt Conveyor

D. Return roller D. Return Roller

D2

d2

L02

b2

l2 L2

c2

c2

Unit: mm Belt폭 Belt

치Size 수

Belt폭 Belt width

width

D₂

ℓ₂

L₂

L02

400

89.1

460

480±0.8

505

400

450

89.1

510

580±0.8

545

450

500

89.1

560

580±0.8

605

600

89.1

660

680±0.8

705

750

114.3

850

880±0.8

905

750

900

114.3

1000

1030±1.0

1055

900

1050

139.8

1150

1180±1.0

1215

1200

139.8

1300

1330±1.0

1355

1400

165.2

1510

1550±1.0

1585

1600

165.2

1710

1750±1.0

1735

1800

165.2

2000

2040±1.0

2075

C₂

8±0.2

d₂

20

25

11.2 ±0.2

30

165.2

2200

2240±1.0

2275

2200

165.2

2400

2440±1.0

2475

3-28

14.0 + 0 - 0.5

500

600

18.0 + 0 - 0.5

1050

22.4. + 0 - 0.5

1400

1200

1600 1800

35 2000

b₂

25.0 + 0 - 0.5

2000 2200

Chapter 4 Hydraulic Equipment

Chapter 4 Hydraulic Equipment

4-1

Chapter 4 Hydraulic Equipment

Table of Contents 1.0

2.0

General ......................................................................................................................

3

1.1

Scope of application ......................................................................................

3

1.2

Scope of supply ..............................................................................................

3

Engineering ...............................................................................................................

3

2.1

Applicable laws and regulations ..................................................................

3

2.2

Drawings and documents ...............................................................................

4

3.0

Design conditions ..................................................................................................

4

4.0

Painting · coloring · packing .............................................................................

5

5.0

Design criteria ........................................................................................................

5

6.0

5.1

General ...............................................................................................................

5

5.2

Control of hydraulic equipment ...................................................................

6

5.3

Equipment specifications ...............................................................................

9

5.3.1

Hydraulic pump .....................................................................................

9

5.3.2

Hydraulic cylinder .................................................................................

9

5.3.3

Valves .......................................................................................................

12

5.3.4

Oil reservoir ............................................................................................

13

5.3.5

Piping, coupling and oil channel ........................................................

15

5.3.6

Accessories ..............................................................................................

17

Fabrication and inspection standards ..................................................................

22

6.1

General .............................................................................................................

22

6.2

Mechanical items .............................................................................................

22

6.3

Electrical equipment and instruments .........................................................

22

6.4

Others .................................................................................................................

22

4-2

Chapter 4 Hydraulic Equipment

1.0 General 1.1 Scope of application These standards are applicable to the design, manufacture, inspection and transporting of the KRI’s hydraulic systems. 1.2 Scope of supply 1.2.1

Range of supply (1) Supply conditions and range shall be governed by the provisions of the purchase technical specifications provided by KRI. (2) Unless explicitly specified otherwise regarding the range of supply, Part 2 Estimation, ISZ-1 shall be applied. General range of supply is as follows: 1) The design, manufacture, inspection and transportation of hydraulic equipments 2) Electrical equipments and instruments 3) Engineering and supervision services for installation and commissioning 4) Submission of drawings and documents 5) Performance guarantee and warranty 6) Installation 7) Cleaning And Flushing oil 8) Lubricating oil for initial filling (Oil recommended by KRI shall be used.)

1.2.2

Items not included in the range of supply General matters not included in the range of supply are as follows. However, such items shall be subject to prior approval by KRI. (1) Hydraulic oil (2) Oil for test(for actuator) (3) Power and utility required for installation and commissioning

2.0 Engineering 2.1 Applicable laws and regulations the Interplant Standards for Steel Industry (IPSS) and the standards of SNI, JOHS, Indonesia Standards (SNI), American National Standard Institution (ANSI), Joint Industry Council, U.S.A (JCI) and Comite European des Transmissions 0leohydrauliques et Pneumatics (CETOP) shall be applied.

4-3

Chapter 4 Hydraulic Equipment

2.2 Drawings and documents 2.2.1 General matters pertaining to the submission of drawings and documents shall be governed by the provisions of Part 2 Estimation, ISZ-1. 2.2.2 The supplier shall submit the following drawings and materials for the installation of equipments and piping: (1) Drawings 1) Circuit diagram 2) Piping drawing for installation 3) Assembly drawing for each unit 4) Parts and equipment layout plan showing location and size of foundation pockets (2) Documents Manuals shall include descriptions relating to operation, function and operating sequence. The description shall contain the following details: 1) Name, catalog number, serial number, model number and manufacturer of each hydraulic equipment components 2) Materials, outer diameter and thickness of the piping and details & type of fitting 3) Operating pressure, nominal maximum pressure, operating power, rpm, direction of rotation of the hydraulic pump and viscosity of hydraulic oil 4) Piston diameter of cylinder, rod diameter, stroke, allowable pressure, velocity, output and efficiency 5) Operation time, e.g. 1 cycle time in case of no-load operation 6) Oil reservoir capacity 7) Type, range of viscosity, output volume, speed range and torque of the recommended hydraulic actuator 8) Capacity, model and filtration grade (absolute and nominal grade) of strainers and filters 9) Manuals shall describe or schematize the work carried by electric or mechanical control devices 10) Pressure-time cycle diagram that shows the maximum value of pressure rise, maximum pulsation pressure and pulsation frequency during the actual operation 11) Actuator’s following operation data shall be submitted: ① Stroke - time cycle diagram ② Speed - time cycle diagram ③ Overall flow rate - time balance diagram between the flow rate supplied from the pump and accumulator and the flow rate consumed at the actuator

4-4

Chapter 4 Hydraulic Equipment

3.0 Design conditions The design conditions shall be governed by the provisions of Part 4 Design conditions, ISZ-1. 4.0 Painting · coloring · packing Painting · coloring · packing shall be governed by the provisions of Part 5 Painting · coloring · packing, ISZ-1. 5.0 Design criteria 5.1 General 5.1.1

If it is difficult or irrational to apply these design standards, such fact shall be submitted to KRI in writing for prior approval.

5.1.2 The following important items shall be considered when designing the hydraulic system: (1) Safety, uninterrupted operation, durability of equipment, convenience of maintenance and low maintenance cost shall be considered. (2) The supplier shall present circuit diagrams and functional data for approval. The final schematic diagram and operation manual shall be in line with the delivered equipment. (3) All equipment maintenance manuals shall include seal numbers and information on spare parts. (4) All components of the system shall be compatible with the hydraulic oil and be installed according to the recommendation of the supplier. (5) As a general rule, hydraulic system and oil lubrication systems shall be independent and separate systems. Dual purpose system shall not be accepted.: 1) The system carries low operating pressures and is used less frequently, with auxiliary functions; 2) Appropriate action can be taken to prevent the deterioration of the hydraulic oil; 3) The drawings specify the use of a dual purpose system; and/or 4) The dual system can function properly with common oil. 5.2 Control of hydraulic equipment 5.2.1

Definitions (1) Manual control: Control by operators (2) Automatic control: Control responding to the system cycle

5.2.2

Equipment protection

4-5

Chapter 4 Hydraulic Equipment

(1) Safety measures 1) Safety devices shall be installed at the pump outlet to protect the

machine against excessive pressure. 2) The pressure control system shall be located in an easily accessible place. 3) Unless explicitly requested by KRI, the pressure and flow control systems shall be equipped with locking device, and shall be adjustable only within the range of the safety control. 4) The circuit must be designed such that the operation cannot be carried out if manual operation is turned off prior to setting the system into a continuous operation mode. 5) If the hydraulic pressure is suddenly shut off, appropriate provisions for safety shall be provided in the circuitory especially in cases of inclined slide or ram. 6) Flexible lines shall be restrained to prevent undesirable movements to reduce possibility of failure. 7) Air bleeds shall be installed on the discharge side of all pumps. In all cases, a check valve shall be installed in the pump discharge line immediately downstream of the bleed valve connections. (2) Pump control If pumps are installed in parallel, appropriate valves shall be installed to prevent effects on the system operation when the pump is installed or moved. (3) Control circuit 1) Position change shall be available. 2) The hydraulic circuit shall be designed in such a way to minimize the generation of heat. 3) For a hydraulic system electrically controlled, the system shall be designed in such a way that its operators and devices can be protected from an accident that may occur due to the damage in the electric circuit. 4) If necessary, a sealed limit device shall be used on the stroke and cycle. Even if the stroke interval is pre-adjusted, it shall be adjustable according to requirements when necessary. 5) Installing stopper ① The precision position control stopper shall be designed in such a way that it will not affect the equipment stopping time even while the stopping position is being readjusted. ② The machine slip safety stopper shall be able to be replaced even when it is impossible to make any adjustment. 6) The hydraulic circuit shall be able to control the minimum surge pressure, and shall be designed and fabricated with parts that can withstand surge pressure. 7) All sensors used to monitor hydraulic systems shall be installed as shown in Attachment 1. (4) Enclosure and compartment for electrical controls.

4-6

Chapter 4 Hydraulic Equipment

1) Enclosure means the hydraulic system housing; the compartment 2)

3)

4)

5)

6)

means the installation bracket of the base frame. The exposed part of the automatic control system likely to be damaged by pollutants and/or sludge shall be appropriately protected and easy to maintain. The automatic control systems shall be composed of a single housing, while the compartment shall be made of at least 14 U.S.S. gauge steel plate or 0.25” steel plate. All enclosures shall be provided with hinged doors or sliding covers. The locking device used on the enclosure shall be intact even if the screws become loose. The automatic control system compartment shall be completely isolated from the coolant, chips, lubricants, cutting oil and other pollutants. Solenoid valves shall be composed under the following conditions: ① To prevent the infiltration of dust and other pollutants, the housing must be made airtight. ② An internal space must be provided where the power cable measuring 150 ㎜ long and tape joints can be included. ③ Ring-type connectors must be used to connect power cables. ④ Screw-type piping connecting method shall be used. ⑤ Captive type bolts shall be used to install the housing cover. ⑥ The housing cover shall be connected with a chain to prevent a drop. ⑦ An appropriate type of manually-operated system shall be provided to enable operation without having to disassemble the system. ⑧ There shall be no electric operation when the housing or cover is being disassembled.

5.3 Equipment specifications 5.3.1

Hydraulic pump (1) Pump shall not be installed inside the reservoir and shall also preferably not be mounted on tank top. (2) Pump shall be connected to the motor firmly so that the center of both axes can match with each other in normal operation. (3) Coupling shall be able to transfer power. (4) The flexible coupling used between the pump and motor shall be subject to prior approval of KRI. (5) Coupling shall be equipped with a detachable safety cover. (6) The name plate shall contain the following information, and shall be attached where it is easily seen. 1) Manufacturer’s name and address

4-7

Chapter 4 Hydraulic Equipment

Model number, type and serial number Flow rate and maximum operating pressure Efficiency (Volumetric efficiency and total efficiency) Required power (7) The direction of the pump rotation shall be marked on the pump itself. (8) The total efficiency of the pump shall be 90% or more. (9) Hydraulic pumps can be selected as follows according to the pressure used. However, different types of pump may be selected according to the characteristics of the system. 2 1) More than 100 kg/cm : piston pump 2 2) 100 kg/cm or less: Vane pump 3) Screw or gear pump may be used as bypass circulation pump but not as system pump. (10) Circulation pumps of adequate capacity with motor shall be provided for parallel filtration and cooling. The circulation pumps shall be screw or gear type. (11) Pumps shall be provided with isolation valves on suction and discharge side to facilitate maintenance. Check valves, relief / unloading valves and pressure gauges shall be provided on downstream side of pumps. 2) 3) 4) 5)

5.3.2

Hydraulic cylinder (1) Hydraulic cylinders shall be designed according to the standards of JCI or CETOP. (2) Hydraulic cylinders shall be designed and fabricated so that it can be safely operated even under the maximum allowable pressure. (3) Cylinders shall be plated as follows: 1) Plating materials: Hard Cr plating 2) Part to be plated: Inside of the cylinder tube and rod surface 3) Plating thickness shall be at least as follows. The plating thickness of the piston rod of the system containing water and steam shall be at least 0.05 or more.

Type of hydraulic oil

Plating thickness (mm) Tube

Rod

Water-glycol group

0.02

0.02

Common mineral oil

0.02

0.02

Phosphate ester group

0.02

0.02

W/O group

0.02

0.02

O/W group

0.05

0.05

Finishing level of the inside of the cylinder tube and rod surface, size tolerance, roundness and cylindricity shall be trimmed or governed by the relative international standards. (4) Materials and standards 4)

4-8

Chapter 4 Hydraulic Equipment

Item Materials of main part Packing Type

Materials

Tube Rod ASTM A512 ASTM SA-194, Gr. 2H A513, A519 DIN 17100 St50-2 Tube diameter of 140mm or less: U-Packing Tube diameter of 140mm or more: VPacking Common mineral oil, P/W group : Rubber particlecontained, urethane (Hardness of Hs90 or more) Water-glycol group: Rubber particle-contained Phosphate ester group: Fluororubber (Viton, Teflon)

Piston ASTM Sa-283 Gr. C or D U-Packing

(5) The cylinder rod stroke tolerance shall be governed by the provisions of

the relative international -class specifications. Stroke 100 or less

Tolerance (mm) 0 – 0.8

Stroke 630 - 1000

Tolerance (mm) 0 - 1.4

100 – 200

0 – 1.0

1000 - 1600

0 - 1.6

250 – 630

0 – 1.25

1600 or more

0 – 1.8

(6) Cylinder fabrication 1) Cylinder tubes and flanges shall be fabricated as follows according

to the operating pressure: Rated pressure (kg/cm2)

Clamping method

70 or less

Screw type

140 or more

Welded type

2) Penetrating bolts shall be used as the cover bolt. Materials shall be

ASTM SA-194 Gr. 2H, using the metric screw threads as prescribed by the relative international standards. (7) When the piston speed would excess 50mm/s, cushion devices shall be

attached to the side of the cylinder head and rod, respectively, and the check valve and the needle valve shall be able to be connected and externally adjusted. (8) Cylinder performance requirements 1) Operability

Test shall be conducted according to the International standards. When the cylinder is horizontally installed and pressure applied to the head under no-load state, the pressure at which the cylinder begins moving shall be as follows. The cylinder shall operate smoothly under the minimum operating pressure. Packing type

Minimum operating pressure

Rod packing: U-Type

3 kg/cm2 or less

4-9

Chapter 4 Hydraulic Equipment

Rod packing: V-Type

5 kg/cm2 or less

2) Pressure resistance

Test shall be conducted according to the International standards. When the cylinder is operated for 2 minutes or longer under the rated pressure, there shall be no distortion with the cylinder, or damage to components. Rated pressure (kg/cm2) Withstand pressure (kg/cm2) 70

140

140

280

210

420

250

500

(9) When the cylinder is reciprocated under the rated pressure used during

the pressure test, the external leakage tolerance of the hydraulic oil shall be less than the following values. There shall be no external oil leakage at all when the cylinder is operating under the maximum allowable rated pressure. Rod Packing type

External oil leakage

U Packing

0.05ml per 100m of stroke

V Packing

0.2ml per 100m of stroke

(10) The internal oil leakage means the amount of oil internally leaked to the

opposite side of the piston when the rated pressure is considered to be 70kg/cm2, and the internal oil leakage shall be less than 2, 3, 3.5 times basis on 70kg/cm2 under the load condition is more than 140kg/cm2 The oil leakage tolerance under the rated pressure of 70kg/cm2 is as follows:

Inner diameter (mm)

Oil leakage (ml/10min)

Inner diameter (mm)

Oil leakage (ml/10min)

40 0.3 140 3.0 50 0.5 160 5.0 63 0.8 180 6.3 80 1.3 200 7.8 100 2.0 210 10.0 125 2.8 250 11.0 (11) The cylinder bore fitting the piston shall be properly drilled to suit the intended purpose, but shall be free of defects, such as pin holes. (12) Cylinders shall be installed in such a way that there will be no force acted upon the direction of the rod circumference or axis due to sliding. (13) Cylinder ends shall be pressure-sealed so that there is no leakage during

4-10

Chapter 4 Hydraulic Equipment

(14) (15) (16)

(17) (19)

5.3.3

operation. All seals used for cylinder must be easily replaceable.. Cylinders shall be installed in such a way that ready maintenance and replacement can be carried out. The piston rod shall be protected appropriately by sealing devices or other protective systems. The rod materials and hardness shall be such that they do not cause any damages to the bore. If necessary, the combined piston-rod seal shall be of an internal type to allow oil to be discharged into the tank. Rods shall be connected to pistons firmly. The cylinder air vent shall be attached to the farthest edge of the cylinder or to an appropriate position to prevent air pockets.

Valves (1) Adjustment type valves shall remain locked by a key and locking device. (2) Valves shall not be installed inside the reservoir. (3) The seal attached to the valves shall be able to be removed or replaced without disassembling each pipe. (4) Seals must be pressure-resistant. (5) Valves shall not cause a harmful surge that may cause damage to the hydraulic system. (6) If the slide or ram is vertically designed or sloped, an appropriate type of protective device shall be arranged to prevent sudden pressure drop when the pressure is shut off. (7) In principle, the valve stand shall be a box type. (8) Air pilot valves shall have speed control plugs on air exhausts. (9) Sub-plate “o” ring mounted valves shall have locating pins or nonsymmetrical bolt holes for fool-proof mounting. (10) Internal leakage shall be separately drained to reservoir to prevent blocking of plunger type controls. (11) Solenoid operated valves shall incorporate the following features: 1) Suitably sealed solenoid enclosure to prevent the entrance of splashing liquids and airborne contamination. 2) Sufficient internal space to incorporate 150mm leads and taped joints. 3) Manual over-rides which can be operated without removing the solenoid covers but which cannot be operated accidentally. 4) Solenoids shall be continuous duty type, with type “H” encapsulated coils. 5) Solenoid indicating lamps. 6) Solenoid valves shall be suitable for DC 24V 7) Solenoid valve electrical leads shall be equipped with vibration proof and weather proof plug type connectors for ease of

4-11

Chapter 4 Hydraulic Equipment

replacement and maintenance. 8) Pilot controlled solenoid operated valves shall be provided with pilot chokes (to control speed of main valve shift to reduce shock). 9) Identification marks stating manufacturer’s name, type, ratings, model no., ports size etc. for valves. (12) Proportional and servo valves shall be provided with electronic card and card holder. (13) Necessary test kit for proportional and servo valves shall be provided. 5.3.4 Oil reservoir (1) The oil reservoir and the hydraulic systems shall be installed on separate foundations. (2) If the reservoir capacity is small (50ℓor less), the hydraulic system may be installed on top of the oil reservoir upon the mutual consent between KRI and the supplier. (3) To filter the supplemental oil, a filter shall be installed on the oil feeding line. (4) A screw-type cap or a permanent type cover shall be installed on the oil feeding mouth. (5) There shall be at least 2 air vents(breather) when oil is being replenished, and these holes shall be protected by air cleaners made of absolute grade sponge of 3m and silicagel chamber acting as moisture absorbent.. (6) The air breather capacity shall be large enough to maintain the atmospheric pressure inside the reservoir. (7) Reservoir shall be designed in such a way that the heat generated from the system can be discharged. (8) A baffle shall be installed to separate air and other contaminants from the oil returned between the suction pipe and return pipe, and the oil returning to the reservoir shall flow along the surface of the baffle. (9) The reservoir foundation shall be raised at least 150mm above the ground level, and the bracket shall have an appropriate type of mounting hole. (10) In general, the reservoir capacity shall be at least 5 times the output of the working hydraulic pump in minutes and must be able to accommodate the oil returning from the system due to gravity when the pump operation is stopped. For smaller system, reservoir capacity may be 8-10 times of working pump flow in minutes (11) Set oil level shall be maintained at an appropriate level during the operation. The minimum fluid level shall be at least 100 mm above the upper most point of the suction nozzle. (12) The level gauge shall indicate a maximum level marking at which oil feeding must be stopped and a minimum level at which oil feeding must start.

4-12

Chapter 4 Hydraulic Equipment

(13) The suction pipe and return pipe shall be installed under the lowest level (14) (15)

(16) (17) (18)

to prevent cavitation and foaming. The oil reservoir shall be designed for the oil to be discharged quickly for cleaning. For hydraulic systems without servo valves reservoir shall be of structural steel. For hydraulic systems wherein servo control valves are used the reservoir shall be of steel. The bottom of the reservoir shall have a minimum clearance of 150 mm from the floor. The hydraulic system shall be configured in the same way as the standard hydraulic system shown in Attachment 2. The magnet separator shall be installed as shown in Attachment 3.

4-13

Chapter 4 Hydraulic Equipment

5.3.5

Piping, coupling and oil channel Piping means all piping materials including pipe, tube, hose and pipe coupling. Oil channel means the passage through which oil passes, except pipe. (1) The suction pipe shall maintain sufficient pressure to prevent pump cavitation. (2) The flow velocity within piping shall be decided based on the following standards. 1) Main Piping Line : 3 ~ 5 m/sec 2) Suction of Pump : 0.5 ~ 1.0 m/sec 3) Return Line : Less than 2m/sec 4) Suction and return piping of Pump : 1 ~ 2 m/sec (3) Causes of surge shall be eliminated. An appropriate type of device shall be installed to protect the piping and joints, preventing damage resulting from the liquid impact generated through the piping network. (4) Piping shall withstand the maximum surge pressure. (5) The pipe connected between valves and the actuators shall be installed firmly to absorb the fluid flow within the piping and to absorb the pipe vibration and shaking. (6) Any type of joints shall be fabricated to meet the standards of MIL-F5506 or other equivalent standards. (7) If flare joints are used, all necessary tools and flare dimensions shall be governed by the standards of SAE AS 4330. (8) The flare angle of the flare joint shall be 37° from the center, or 74° from both ends. Technical requirements shall be governed by the standards of MIL-F-5509. (9) The joints, heterogeneously combined with metal to metal seals or pressure seals, shall be used on the pipe-thread according to the standards of UNF Straight Thread. (10) All piping shall be connected with NPTF Dry Seal Taper Thread. (11) All piping joints shall be designed and mounted in such a way to allow quick removal or fabrication. (12) The recommended diameters of the pilot and power line are 1/4, 5/16, 3/8, 1/2, 5/8, 3/4,7/8, 1, 11/4 and 2 1/2 inches. For special lines like air pressure lines or metered flow lines, different sizes may be used upon the mutual consent between KRI and the supplier. 1) Tubing shall be of the standard drawn or welded type, using ASTM 106 Grade B materials. (13) Burrs shall be removed from the pipe, oil channel joint, cast core or the processed holes. (14) The pipe used to connect components shall be composed of one unit of pipe and joints shall be used only to assemble and/or adjust pipe so that pipe is easily removed (15) All piping shall be clamped firmly to prevent vibration or shaking.

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Chapter 4 Hydraulic Equipment

(16)

(17)

(18)

(19) (20)

(21)

(22) (23) (24)

Intervals between the pipe clamps shall be as shown in Attachment 3. Flange joints shall be used and tightened to render airtightness. If the system caries pressure exceeding 180kg/cm2, all welded parts shall be annealed to remove internal stress. For a hose exposed to pressure of 10kg/cm2 or more, at least 5 times the safety factor shall be provided. If pressure is less than 10kg/cm2, plastic tubes can be used. The ends of the hose and plastic tube shall be attached vertically and shall be long enough to avoid abrupt bending or excessive tension. If the hose or the plastic tube can be supported appropriately to prevent bending, they can be attached horizontally. In case of the equipment for outside drainage, oil shall be drained into the reservoir or a separate vent manifold. Pipe markings In case disassembled parts are moved for repair or shipment, parts of the pipe shall be properly marked according to drawings, and appropriate protective devices shall be provided. All male screws shall be covered by sleeves, and all pipe holes and the female screws shall be protected by plugs connected to the pipe with chain. Pipe pressure measuring points are as follows. They shall be located within easily accessible places, and the results of the pressure test conducted after assembling shall be submitted to KRI. 1) Pump inlet and outlet 2) Accumulator circuit 3) Front and back of the pressure adjusting valve, flow control valve and the servo valve 4) Actuator rod and head 5) Front and back of each filter 6) Position agreed upon between KRI and the supplier All measuring points shall be protected by the caps connected with chain. The cap shall be able to block oil and air. To ensure accurate inspection of the system operation, all systems shall have a pressure gauge and other pressure-measuring units with hose. Welding method of the piping shall be carried out as follows according to the thickness of the pipe, while the strap shall be less than 2mm. The welded part shall undergo RT 100% to avoid defects.

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Chapter 4 Hydraulic Equipment

Item Less than 6t 6t or more

Welding method

Remarks

Overall TIG welding TIG welding shall undergo a gas purging. 1 PASS: TIG, (Carbon steel: Nitrogen, STS: 2 PASSES or more: Arc Argon) welding with covered electrode (25) The welded part, during a butt welding, shall be fabricated as shown on Attachment 5. (26) The piping shall not be used as supports for valves or other devices. (27) Flushing piping and valve shall be installed before actuator in order to flushing easily and not to disassembly actuator when the oil would be contaminated.

5.3.6 Accessories (1) Heat exchanger 1) Heat exchanger shall be easily disassembled for repair or replacement. 2) Heat exchanger shall be equipped with an automatic temperature control, and shall always be protected from high pressure or surge pressure. 3) Diagram and the heat exchanger itself shall carry clear information about the structure, pipe diameter, capacity and flow rate. 4) If a circulating type heat exchanger is used, oil and cooling water temperature must be able to be checked at the inlet and outlet of the exchanger. 5) Shell and tube type heat exchanger shall be designed as per Tubular Exchanger Manufacturers Association (TEMA) standards or the coolers of the standards or the codes of standards institution of the country of origin. Plate type heat exchangers shall be designed as per manufacturer’s standard. Plate type heat exchangers shall be gasketed design. (2) Filter and strainer 1) Filter shall be able to be repaired by disassembling only 1 unit of its parts. 2) Arrangement should be such that filter element can be changed without disruption in system operation. To this effect, twin filters may be considered at all places.. 3) Filter shall be designed in such a way that mechanical or electric differential pressure indicator can be installed. 4) All hydraulic systems within servo valves shall be equipped with pressure filters, circulation filters and return line filters of 10 micron, 5 micron respectively. Hydraulic systems with servo valves shall be provided with pressure filters, circulation filters and return line

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Chapter 4 Hydraulic Equipment

filters 3 micron, 5 micron and 10 micron respectively. These filters shall have differential pressure switch connected across inlet and outlet to give audio-visual indication of clogging. For hydraulic systems with servo valves, 1 micron parallel filtration system shall be provided. 5) Filter housing ① Filter housing shall be of rustproof materials, or its surface shall be properly treated to prevent corrosion. And it shall not be of welded structure. In addition, fatigue test shall be conducted according to the standards of NFPA T2.6.1. If the operating pressure is 250Bar, test shall be carried out based on the standards of NFPA T2.6.1. ② The filter housing shall guarantee pressure-resistance that ensures no oil leakage or filter stability under a test conducted with pressure 150% of the maximum level. ③ The filter housing shall be designed in such a way that the inlet pressure will not be applied directly to the filter element. ④ If the system operating pressure exceeds 35bar, no aluminum shall be used. ⑤ The by-pass valve used for the by-pass filter shall allow passage of the entire amount of oil, and shall operate regardless of the filter element and the differential pressure indicator. 6) Filter element ① Filter element shall be of a single structure. ② Standard O-rings, which are suitable to the hydraulic oil of mineral oil group, water-glycol group and polyol ester group, shall be used. ③ If the filter element is used on the by-pass type housing, the collapse pressure shall be greater than 10Bar. ④ Filter elements are throwaway type and cannot be cleaned and reused.. 7) Differential pressure indicator ① The differential pressure indicator shall be a detachable type, and can be tested at any time when needed. ② The filter element shall be able to measure the differential pressure occurring at the front and rear of the filter, but shall not be connected to the by-pass valve or to the element. ③ The visual checking differential pressure indicator shall indicate the current filter differential pressure even when the system is not operating.

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Chapter 4 Hydraulic Equipment

8) The grading of the filters installed on the hydraulic system are as

follows:

105m

Pressure Line Filter 3m

Return Line Filter 3m

105m

6m

105m 105m

Strainer Size

System type System using servo valve Proportional control valve, High-pressure system greater than 210Bar Low-pressure system less than 210Bar Common hydraulic power unit Lubricating system for low viscosity not exceeding 100Cst

Oil Inlet Line Filter

Circulation Filter

3m

3m

6m

3m

6m

12m

12m

3m

12m

12m

-

3m

12m

9) Filter shall be an absolute filter, and the time weight filtration

performance coefficient shall be 200 or more based on the result of the ISO 4572 Multi-pass Test. 10) The hydraulic system shall be composed of the pressure, return and circulation line filter in the same system, and the filtration grading shall be the same. 11) Filter capacity review ① Line filter The initial differential pressure of the line filter shall be within the following standards based on the fluid’s specific gravity and viscosity under the system’s maximum flow rate. Place of installation Pressure Return 12)

Type

Allowable initial differential pressure (kg/cm2g)

By-pass Non by-pass By-pass

1.3 or less 1. 5 or less 0.5 or less

The following types of filters shall be installed according to the places of filter installation:

Location of installation

Filter type Manifold block Filter mounted type Duplex type Duplex type Filtering M/C Filtering unit

Pressure Return line Circulation

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Chapter 4 Hydraulic Equipment

13)

Metals and seal materials used for filters shall be selected to fit the oil used. Mineral Oil Group

Item Metal suitability

Seal, Packing, O-ring

Suitable

Unsuitable

May be used NBR, ABR, VITON, CR IIR, EPR

Polyol-ester May be used

Water Glycol Zn, Mg, Cd cannot be used

NBR, ABR, Zn, ABR, VITON VITON, CR

IIR, EPR

Silicon, Poly Urethane+Cork

Phosphate May be used NBR, IIR, EPR, Silicon NBR, ABR,Poly Urethane+Cork, Leather

14) The capacity of the strainer attached to the pump shall be at least 2

times the pump suction capacity. 15) Strainers shall be able to be repaired without having to empty the reservoir, and shall be equipped with a differential pressure indicator to check the status of differential pressure. 16) The bypass filter shall be able to filter, during a period of 1 hour, the entire amount of oil in the reservoir. 17) To separate iron particles that cannot be filtered through the filter or strainer, a magnet with sufficient magnetic power and capacity shall be installed inside the reservoir as shown in Attachment 3. 18) Magnet shall be installed between the return side and the suction strainer, and shall be replaced easily for the purpose of manufacture. (3) Air breather 1) Air breather is used to suck or discharge external air to maintain the

pressure above the oil level inside the tank to that of atmospheric pressure when the tank oil level changes upwards or downwards. The breather shall be installed at a point 15cm from the top of the hydraulic tank so that the pump can suck operating oil smoothly. 2) The internal element shall remove dust extant in air, and oil drops being sucked in from outside. 3) The air breather shall be composed of the element, cover and differential pressure indicator. If the element is clogged by foreign matters, the system shall be able to indicate the time of element replacement through the generation of differential pressure. 4) The maximum air breather capacity shall be calculated as follows: Maximum air breather capacity = No. of pumps x Maximum pump flow

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Chapter 4 Hydraulic Equipment

5) Element size standards

Item

Element size

Servo valve controllers Proportional control system High-pressure facility with capacity 210Bar or more Common hydraulic facility

Not exceeding 3m Not exceeding 6m Not exceeding 12m

(4) Seal 1) Seals shall be made of appropriate materials that are resistant to the 2) 3) 4) 5)

hydraulic oil. Seals shall be of a pressure seal type. The allowable seal clearance shall be able to prevent the seal from being pushed by the pressure. Self-seal packing shall be used within the functional limit of the self-seal. Bed slide or the ring packing used on the moving part shall be designed in such a way that replacement of the system is easy.

(5) Accumulator 1) To be able to safely disassemble the accumulator, an appropriate

type of device shall be installed to remove gas from the accumulator. 2) Gas filling systems, pressure gauges and other auxiliary equipment shall be supplied along with the accumulator to maintain an appropriate level of operating pressure. 3) Accumulator shall always indicate the following information: ① Manufacturer’s name and address ② Model number ③ Serial number ④ Nominal pressure ⑤ Gas filled ⑥ Accumulator capacity

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Chapter 4 Hydraulic Equipment

6.0 Fabrication and inspection standards The Fabrication and inspection standards for the materials to be supplied shall follow the following inspection standards issued by KRI. 6.1 General Standards commonly applicable shall be governed by the provisions of the KRI inspection standards: PS-N-05-00. 6.2 Mechanical items 6.2.1 Pump: PS-N-05-03 6.2.2

Valve: PS-N-05-06

6.2.3

Expansion joint: PS-N-05-07

6.2.4

Heat exchanger: PS-N-05-10

6.2.5

Pressure containers: PS-N-05-11

6.2.6

Steel structures: PS-N-05-17

6.2.7

Cylinder: PS-N-05-18

6.2.8

Coupling: PS-N-05-39

6.3 Electrical equipments and instrumentation 6.3.1

Panel: PS-N-05-24

6.3.2

Motor: PS-N-05-25

6.3.3

Cable: PS-N-05-30

6.4 Others Painting and packing: PS-N-05-03

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Chapter 4 Hydraulic Equipment

Attachment 1.

Hydraulic system monitoring (Example)

Sensor position 1. Sampling cock - Front and rear of filter (S2, S3, S4, S5, S6) - Tank (S1): Lower side, middle and top of tank (6 each) 2. Pressure sensor or check point - Front of pump (P1-1) and a tank (P1-2): Vacuum pressure - Rear side of pump (P2, P11) - Front and rear of pressure control (P2, P3, P11, P10) - Actuator (P4, P5, P6, P7, P8, P9) - Filter (P12, P13, P14): Differential pressure indicator 3. Temperature sensor - Cooler and heater (T1, T2) - Tank (T3)

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Chapter 4 Hydraulic Equipment

Attachment 2.

Standard hydraulic system circuits C

SERVO-VALVE

ACTUATOR

B

I D

A

E

WASTE PART

CLEAN PART

F

G

M M M H

4-23

Explanation

기 설명 of호 symbols A PUMP 보호용 STRAINER (A) Pump protective strainer SYSTEM 보호용 FILTER filter B(B) System protective SERVO VALVE 보호용 FILTER Servo valve protective C(C) filter SYSTEM에서 생긴 오염물 제거용 D(D) Filter used to remove FILTER pollutants generated by the 충진용 FILTER E OIL system (E) Oil filling filter 순환용 FILTER F(F)OIL Oil circulating filter MAGNET FILTER G(G) Magnet filter (H) Heat exchanger 열교환기 H (I) Air breather I AIR BREATHER

Chapter 4 Hydraulic Equipment

Attachment 3. Magnet separator 1. General specifications

2.

Face and side

STS 304

Bottom

Epoxy resin, SS400, STS 304

Magnet

Ceramic, strontium, ferrite

Installation face

Chromium-molybdenum steel

M/S standards

Q = Tank capacity (ℓ) P = Pump suction (ℓ/min) N = No. of micro-separator (MSR 200 type)

A. Tank for water-glycol group, phosphate ester oil and emulsion oil

B. Mineral oil group oil reservoir

Magnet separator for floating pollutants

Magnet separator for sediments

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Chapter 4 Hydraulic Equipment

Attachment 4.

Pipe clamp types X: Inappropriate,

Environment

Standard block 표준Block Heavy Block U- USterBolt Band PP* AI* PP Al Iron ite Excessive열 heat 과도한

X

X

환 Water 수분 경 Acid,알카리 and alkali 산, Load stress

Pulsation 하 맥동 중 Vibration 진동 응 력 충격 Shock

X X

△

X

△

Remarks 비고

Better quality Stainless강 than stainless △ 재질의 Bolt steel양호 bolt 보다 Low-pressure

저압 pipe,PIPE, U-band U-BAND

X X

△: Caution

X

X

X

Pressure

Low pressure

2 저압(10kg/cm ) (10kg/cm2)

압 Medium pressure 중압(≤70k) (≤70k) 력 High pressure 고압(≤210k) (≤210k) P (pressureLine) line) P(압력

X X

△

X

1. Used in

1.맥동이 심한 places with severe 곳에 적용 pulsation 2.매우 중요한 2. Extremely important 개소 places 3.요소에 진동, 3. Places having 충격 등이 vibration and/or shock 있는 개소

R (ReturnLine) line) R(복귀 Pipe type

Pipe S (Suction line) S(흡입 Line) 종 PP(Pilot Line) PP(Pilot Line) 류 Dr(Drain Line) Dr(Drain Line)

Better than stainless steel bolt

Sensor Sensor

Pipe 경

10A 15A 20A 25A 32A 40A . . 150A

#4

#5

 Standard types are used in the ·#4 범위는 range marked 표준 by #4. 형이

사용됨 ·#5  Used범위는 in places 하중이 with less 작은 load in the range 곳에 적용 marked by #5.

* PP: Polypropylene * Al: Aluminum

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Chapter 4 Hydraulic Equipment

2.

Distance between clamps Optimal Distance Between Clamps Pipe Diameter 6 – 20A

Medium and Low Pressure 1.0 – 1.5m

25 – 50A

1.5 – 2.0m

 2.0m

65 – 125A

2.0 – 3.0m

 2.5m

150 – 500A

2.5 – 5.0m

 3.0m

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High Pressure  1.5m

Chapter 4 Hydraulic Equipment

Attachment 5. Shapes of the butt-welded face 두께(t) 면가공 Thickness (t) Face Treatment

Applicable Piping (Thickness) 적용배관(두께)

형상 Shape

SCH 80 2∼6 mm

V형 V type

SCH 160

6A(2.4) 8A(3.0) 60

R=1∼2mm

。

t

10A(3.2)

15A(4.7)

15A(3.7)

20A(5.5)

20A(3.9) 25A(4.5)

R

32A(4.8) 40A(5.1) 50A(5.5)

6∼25 mm

V(Y)형

25A(6.4) 32A(6.4)

R1:2∼3 mm

40A(7.1)

R2:1∼2 mm

50A(8.7)

Note) R1: Root spacing; R2: Root face

4-27

65A(7.0)

65A(9.5)

80A(7.6)

80A(11.1)

90A(8.1)

90A(12.7)

100A(8.6)

100A(13.5)

120A(9.5)

120A(15.9)

150A(11.0)

150A(18.2)

Chapter 5 Cooling Tower

Chapter 5 Cooling Tower

5-1

Chapter 5 Cooling Tower

Table of Contents 1.0

2.0

3.0

General ......................................................................................................................

3

1.1

Scope of application ......................................................................................

3

1.2

Definition of terms ..........................................................................................

3

1.3

Scope of supply ..............................................................................................

4

1.4

Drawings and documents ...............................................................................

5

Design conditions ..................................................................................................

5

2.1

General ...............................................................................................................

5

2.2

Design standards and regulations ................................................................

5

Engineering services and supervision .................................................................

5

3.1

Engineering services ........................................................................................

5

3.2

Supervision .......................................................................................................

6

4.0

Painting · coloring · packing ...............................................................................

6

5.0

Design criteria ..........................................................................................................

6

6.0

7.0

5.1

Design criteria by type ....................................................................................

6

5.2

Electrical equipment and instrumentation .................................................

9

Fabrication and inspection standards ..................................................................

9

6.1

Mechanical equipment ...................................................................................

9

6.2

Steel structures .................................................................................................

10

6.3

Electrical equipment and instrumentation ...............................................

10

Acceptance Test ........................................................................................................

10

5-2

Chapter 5 Cooling Tower

1.0 General 1.1 Scope of application This standard is applicable to general technical specifications used to purchase cooling tower facilities at steel plants. 1.2 Definition of terms 1.2.1 Design standard cooling capacity : Cooling capacity of the designed number of systems at the standard design temperature 1.2.2 Performance curves : Curves which indicate thermal characteristics of testing equipment or the equivalent cooling towers to the equipment 1.2.3

Water temperature range : Water temperature difference between inlet and outlet

1.2.4 Counter flow cooling tower : Cooling effected by the counter flow of water and air 1.2.5

Cross flow cooling tower : Cooling effected by the cross flow of water and air

1.2.6

Indonesian design criteria for cooling tower area as follows: (1) Design wet Bulb temperature : 29°C (2) Cooling range for indirect cooling : water circuits 10°C ~4°C. (3) Cooling range for direct cooling water circuits of Blast Furnaces, Converters, casters, mills: °C ~22°C. (no indonesian standard) (4) Cold water temperature :34°C (5) Type of tower : Mechanical induced draft type with either cross flow or counter flow arrangement of air flow for industrial cooling towers. (6) Type of fill : Splash bar for industrial towers. Film type for small size towers of air conditioning system. (7) Material of construction of the industrial cooling tower (considering river water) shall be as follows:

5-3

Chapter 5 Cooling Tower

Tower : RCC (for flow 500 cum/hr & above)/Timber (for flow less than 500 cum/hr) Fill : PP/PVC Fan Stack : RCC/FRP Fan blades : FRP Draft eliminator : PVC Fittings and fixtures : Hot deep galvanized mild steel (8) Type of installation - On ground basin preferred. However, under ground basins are also used for some plants. (9) The basin shall have a capacity of not less than 10 minutes of flow of cooling water. The basin shall be constructed in compartments with necessary screen and gate arrangements at outlet to facilitate isolation. (10) Cooling tower shall be designed for 20% hydraulic overloading. No stand by cell is recommended. (11) Drift eliminator shall be designed to reduce the water losses through drift to less than 0.01% of the flow. (12) Hot water distribution basin cover of FRP construction to be provided for cross flow tower. (13) Vibration limit switch shall be provided for each fan assembly (14) Adequate valves shall be provided in the hot water distribution pipe work for proper isolation and control. 1.3 Scope of supply 1.3.1 Range of supply (1) Supply conditions and range shall be governed by the provisions of the purchase technical specifications or requirements provided by KRI. (2) Unless specifically provided separately regarding the range of supply, Part 2 Estimation, ISZ-1 shall be applied in common. General range of supply is as follows: 1) Cooling tower design, manufacture, inspection, and transporting ① Main equipment Structure (steel and FRP), motor, reducer, fan blade, fan boss & fan, fan stack, filler & eliminator, hot-water distribution system, and louver(FRP) ② Accessorial equipment Foundation anchor bolt & nut, lifting lug, counter flange, and protection cover ③ Electrical systems and instrumentation - Power & control cable and panel - Vibration switches and other types of sensors ④ Chemical feeder (In case of a blanket order covering indirect

5-4

Chapter 5 Cooling Tower

cooling system and accessorial equipment) 2) Engineering and supervision services for installation work and operation 3) Submission of drawings and documents 4) Performance guarantee and warranty 1.3.2 Items out of the range of supply (1) Unless specifically provided separately regarding the range of supply, Part 2 Estimation, ISZ-1 shall be applied in common. General range of supply shall follow the KRI’s purchase specifications. (2) Chemical feeders (In case the cooling tower is included in the water treatment system) (3) Works related to construction 1.4 Drawings and documents 1.4.1 Performance curves, characteristics curves, and capacity calculations shall be submitted. 1.4.2

General matters pertaining to the submission of drawings and documents shall be governed by the provisions of Part 2 Estimation, ISZ-1.

2.0 Design conditions 2.1 General Design conditions shall be governed by weather and geographical conditions of the area where equipment is installed. Design conditions areas shall be governed by the provisions of Part 4 Design conditions, ISZ-1. 2.2 Design standards and regulations SNI, KS, BIS, CTI Code (Cooling Tower Industrial Association of the U.S.A.) and industrial standards of other countries may be applied. However, KRI’s prior approval is required in relation to the use of such standards

3.0 Engineering services and supervision 3.1 Engineering services General common matters shall be governed by the provisions of Part 3 Engineering, ISZ-1. Detailed range of application is as follows: 3.1.1 Basic design (BD) Designs used to decide specifications and drawings forming the basis of the

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Chapter 5 Cooling Tower

equipment purchase, detail design, and shop drawings based on the basic plan include the following: (1) Basic engineering Examination of water & heat balance, utility, and electric requirements (2) Basic design (BD) General common matters shall be governed by the provisions of Part 3 Engineering, ISZ-1. 3.1.2

Detail design (DD) Detail design is prepared based on the basic design; and common matters shall be governed by the provisions of Part 3 Engineering, ISZ-1.

3.2 Supervision General common matters shall be governed by the provisions of Part 3 Engineering, ISZ-1. 4.0 Painting · coloring · packing Painting · coloring · packing shall be governed by the provisions of Part 5 Painting · color · packing, ISZ-1. 5.0 Design criteria These design criteria are applied when preparing the basic and detail design in accordance with Paragraph 2.2 Design standards and regulations.

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Chapter 5 Cooling Tower

5.1 Design criteria by type Item

Counter Flow

Cross Flow Lownoise type 100RT or more 3 100 m /hr (100~25 or more 0 RT Series)

FRP Round

R.C structure

5~1000RT

500m3/hr or more

Frame

-FRP

-R.C

-H.D.G

Filler & Eliminator

-PVC

-PVC -Wood

Casing

-FRP

-R.C

-PVC -PVC -Wood -FRP/ -Asbestos -PVC Cement -FRP Board -PVC

Structure type

Applicable capacity

Steel Structure

R.C structure

Steel structure

500 m3/hr or more

100 m3/hr or more

-R.C

-H.D.G

-PVC -Wood

-PVC -Wood -FRP/ -Asbestos Cement Board -PVC -FRP -Asbestos Cement Board -PVC

Material

Louver

Note)

-Asbestos -PVC Cement -FRP Board -FRP

-FRP

Fan Stack

-FRP

-FRP -R.C

Fan Blade

-FRP

-FRP

-H.D.G

-FRP SS400+H DG

-FRP

-R.C

R.C

-FRP -R.C

-FRP -FRP -FRP -Aluminum Aluminum

-FRP -HDP -FRP -Aluminum

1. H.D.G(Hot Deep Galvanized) 2. FRP(Fiber Reinforced Plastic) 3. PVC(Poly Vinyl Chloride)

5.1.1 Structures (1) Major structure material quality shall be governed by the provisions of Paragraph 5.1, Design criteria of each type. (2) Structures shall be designed to withstand the design standards of the maximum wind velocity ( 25 m/sec). (3) Access shall be made from the fan deck to the eliminator, hot-water distributor systems, and near the fan through the ladder. The fan stack shall be equipped with an access door, and a deck installed near the reducer for inspection and repair.

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Chapter 5 Cooling Tower

5.1.2 Motor (1) Motor shall be made in accordance with ISZ-7. (2) Flexible disc coupling shall be used to connect axis of the motor and the reducer. (3) Motor shall be started as follows according to motor power: Less than 75 kw : Direct starting 75 kw or more : Y-Δstarting

5.1.3 Reducer (1) Bevel gear shall be used, while the lubrication system installed outside the fan stack. Oil level gauge and drain lines are also installed. (2) The drive part bearing shall be greased from the external side of the fan stack. 5.1.4 Fan blade (1) Fan blade material shall be governed by the provisions of Paragraph 5.1, Design criteria for each type (2) The fan blade pitch shall be adjusted at site. (3) The fan blade shall be designed and fabricated in such a way that air flow is smooth and wind volume can be adjusted, in addition to providing accurate balancing which eliminates noise and vibration. 5.1.5 Fan stack (1) The shape shall be a bell mouth type. (2) The gap between the fan blade and the fan stack shall be 0.5% or less of the blade diameter. (3) The stack shall be located high enough (1.5m) so that the air discharged from the fan is not recirculated. 5.1.6 Filler & Eliminator (1) Material shall be governed by the provisions of Paragraph 5.1, Design criteria for each type. (2) The dispersed loss of the eliminator shall not exceed 0.01% of the total circulation. 5.1.7 Louver (1) Materials shall be governed by the provisions of Paragraph 5.1, Design criteria for each type. (2) External air shall be evenly distributed into the cooling tower. (3) The system shall be structured in a way so that dispersion is minimized.

5.1.8 Hot-water distribution system

5-8

Chapter 5 Cooling Tower

(1) The cooling tower shall be operated even when each cell is separated. (2) The injection nozzle shall be so designed that the injected water forms a

shape of a cone for even distribution of water. 5.1.9 Others (1) Materials for every bolt, nut and, washer shall be stainless steel. (2) To prevent rust, all steel structures shall undergo the H.D.G(Hot Deep Galvanized). (3) Hoist rails shall be installed on top of the tower, if needed, in a place where a truck crane cannot make an access. 5.2 Electrical equipment and instrumentation 5.2.1

General General conditions covering the electrical systems and instrument design conditions and engineering services shall be governed by the provisions of Chapter 7 Electrical equipment, and Chapter 8 Instrumentation, ISZ-2.

5.2.2

System configuration The cooling tower shall be installed in such a structure that it can be operated at site, and the operating condition manipulated and/or monitored by the site operation and the central operation room.

5.2.3

Control system A vibration sensor shall be installed on the cooling tower to protect the equipment in case any abnormal vibration should occur.

6.0 Fabrication and inspection standards 6.1 Mechanical equipment 6.1.1

This standard shall be prepared to satisfy Paragraph 5.1 Design criteria for each type and the required performance.

6.1.2

The top fan drive systems shall be delivered in the assembled conditions after completing an independent performance test. If overall fabrication of the drive system is needed for the site situation, a prior discussion shall be held with KRI.

6.1.3 Inspection standards covering mechanical devices shall be governed by the KRI inspection standards:

6.2 Steel structures

5-9

Chapter 5 Cooling Tower

6.2.1

Steel structures shall be fabricated according to the basic, detail design drawings and Paragraph 5.2 Design standards for parts.

6.2.2 The unit of structure that can be transported shall be shop fabricated and assembled as much as possible prior to delivery. For equipment that shall be provisionally fabricated at plant prior to delivery or those to be delivered piece by piece shall require prior discussion with KRI. 6.2.3 For equipment which is likely to be deformed after its fabrication, transporting, and installation, appropriate tools for preventing deformation (jigs) or lifting lugs shall be provided to prevent such deformation or distortion, as needed. 6.2.4 In case of bolts, nuts, and fittings used to assemble equipment, spare items shall be provided in addition to the quantities shown on drawings. 6.2.5 The steel structure inspection standards shall be governed by the provisions of the KRI inspection standards: 6.3 Electrical equipment and instrumentation 6.3.1

The fabrication and inspection standards covering electrical equipment and instrumentation shall satisfy the provisions of Paragraph 5.3.

6.3.2 The fabrication and inspection standards covering electrical equipment and instrumentation shall be governed by the provisions of the following KRI inspection standards:

7.0 Acceptance Test It shall be done according to CTI ATP 105 Code.

5-10

Chapter 6 Dust Collectors

Chapter 6 Dust Collectors

6-1

Chapter 6 Dust Collectors

Table of Contents 1.0

2.0

3.0

General ......................................................................................................................

3

1.1

Scope of application ......................................................................................

3

1.2

Scope of supply ................................................................................................

3

1.3

Drawings and documents .............................................................................

3

Design conditions ..................................................................................................

3

2.1

General .............................................................................................................

3

2.2

Design standards and regulations ..............................................................

3

Engineering services and supervision .................................................................

3

3.1

Engineering services ........................................................................................

3

3.2

Supervision .......................................................................................................

4

4.0

Painting · coloring · packing .............................................................................

4

5.0

Design criteria ..........................................................................................................

5

6.0

5.1

General .............................................................................................................

5

5.2

Bag filter ............................................................................................................

5

5.3

Dry electrostatic precipitator .........................................................................

6

5.4

Wet scrubber .....................................................................................................

8

5.5

Common equipment ........................................................................................

8

Fabrication and inspection standards ...................................................................

9

6.1

Mechanical equipment ...................................................................................

9

6.2

Steel structures .................................................................................................

10

6.3

Electrical equipment and instrumentation .................................................

10

6-2

Chapter 6 Dust Collectors

1.0 General 1.1 Scope of application This standard is applicable to general technical specifications used to purchase bag filter, dry electrostatic precipitator, wet scrubber used at steel plants. 1.2 Scope of supply 1.2.1 Supply conditions and range shall be governed by the provisions of the purchase technical specifications or requirements provided by KRI. 1.2.2 Unless specifically provided for separately regarding the range of supply, Part 2 Estimation, ISZ-1 shall be applied in common. 1.3 Drawings and documents General matters pertaining to the submission of drawings and documents shall be governed by the provisions of Part 2 Estimation, ISZ-1. 2.0 Design conditions 2.1 General Design conditions shall be governed by weather and geographical conditions of the area where equipment is installed. Design conditions covering Cilegon areas shall be governed by the provisions of Part 4 Design conditions, ISZ-1. 2.2 Design standards and regulations 2.2.1 The emission levels of particulate and other pollutant gases from each source shall conform to the requirements of Indonesia Environment Protection Act. 2.2.2 SNI, KS,BIS, State / Central Pollution Control Boards as per the stipulation of the latest Air (Prevention and Control of Pollution) Act and the industrial standards of other countries may be applied. However, KRI’s prior approval is required in relation to the use of such standards. 3.0 Engineering services and supervision 3.1 Engineering services General common matters shall be governed by the provisions of Part 3 Engineering, ISZ-1. Detailed range of application is as follows:

6-3

Chapter 6 Dust Collectors

3.1.1

Basic design (BD) Designs used to decide specifications and drawings forming the basis of the equipment purchase, detail design and shop drawings based on the basis plan include the following: (1) Basic engineering 1) Engineering plan 2) General plant layout 3) Flow diagram 4) Hood & duct arrangement 5) Material balance, utility, electric consumption review (2) Basic design (BD) condition 1) Dust collector specifications Dust collector types, weight, filtration velocity, temperature, distribution of dust grading, and gas properties. 2) Preparation of equipment technical specifications Dust conveyors, bag cleaning systems, filters, compressed air suppliers, fan, and stacks 3) Out-put : Basic drawing and Document

3.1.2

Detail design (DD) (1) Detail design shall be prepared based on results of the basic design for application at the plant or at site. (2) Construction drawings shall be prepared for field work. (3) List of materials for each equipment and bills of quantities

3.2 Supervision Shall be governed by the provisions of Part 3 Engineering, ISZ-1

4.0 Painting · coloring · packing Shall be governed by the provisions of Part 5 Painting · coloring · packing, ISZ-1

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Chapter 6 Dust Collectors

5.0 Design criteria 5.1 General 5.1.1

System shall be designed after carefully checking the amount of gas, dust concentration in the dust characteristics temperature of gas provided by KRI in relation to the objects to be collected.

5.1.2

Design criteria shall be applied according to the provisions of Paragraph 2.2 Design standards and regulations, when preparing basic and detail designs.

5.2 Bag filter 5.2.1 Filtration velocity The filtration velocity, when calculated based on the flow rate through a unit area of the filter bag, is as follows: V = Q / A V : Filtration velocity (m/min) Q : Volume of flow rate (m3/min) A : Filter bag area (m2) The filtration velocity is an important factor affecting the dust collector efficiency. The filtration velocity shall be designed considering the dust characteristics within the range of 1.3 ~2.0m/min. 5.2.2

Filter bag (1) The filter media shall carry acid, alkali, heat, corrosion and abrasion resistance plus mechanical strength. (2) The filter media shall be strong enough to last 1 year or more before replacement. (3) The filter bag seams shall be properly sewn to increase the dust collector efficiency and increase the bag life span. (4) Retainer shall be designed in consideration of the wire size, spacing between lines and intervals between reinforced wires and the dust collector pressure loss. (5) Bag shall be designed for easy replacement.

5.2.3

Casing (1) The casing shall consist of one or many collector chambers and shall firmly be supported while maintaining total airtightness.

6-5

Chapter 6 Dust Collectors

(2) The casing pressure loss shall be within 200mmAq and shall be free of

quality deterioration and contraction.. (3) To prevent damage resulting from the friction between the filter bags,

the tub sheet hole shall be adequately spaced. (4) Sufficient number of walkways and manholes shall be provided to

facilitate inspection and repairs. (5) The casing steel plate shall be 4.5mm or more in thickness equivalent to

carbon steel quality. (6) Manometers shall be installed to check the bag replacement time based

on the differential pressure. (7) Tube sheet hole shall be machine drilled. (8) Installing pre-dust shall also be considered taking into account the dust

grading. 5.2.4 Hopper (1) Round or square inspection man holes shall be installed at the bottom. 。 (2) Hoppers shall bear an angle of 60 or more and a rapper shall be installed to remove the accumulated dust. (3) The hopper steel plate shall be 4.5mm or more in thickness equivalent to carbon steel quality.

5.2.5

Slide gates, rotary air lock valves, screw conveyors, pneumatic conveyors and chain conveyors shall be installed to discharge and convey dust accumulated in the hopper.

5.2.6 Bag cleaning Bag cleaning is classified into intermittent bag cleaning, periodic bag cleaning, and continuous bag cleaning which shall be selected according to the operating conditions. As a general rule, the Pulse jet method used for bag cleaning. 5.3 Dry electrostatic precipitator 5.3.1 Chamber (1) The chambers shall be totally closed to ensure perfect air-tightness and shall be supported with reinforcing materials. (2) The chamber pressure loss shall be within 30mmAq and shall be free of quality deterioration and contraction. (3) The traveling speed of dust in the chamber is an important factor affecting the dust collector design, which is decided according to the types of dust, processing efficiency and the type of discharge electrodes, through a separate approval process. (4) To enable the passing gas to maintain temperature higher than the dew point, appropriate types of heat insulating and heating system shall be installed.

6-6

Chapter 6 Dust Collectors

(5) Sufficient number of walkways and manholes shall be provided to

facilitate inspection and repairs. (6) The gas distribution plate shall be designed in such a way that even gas

flow can be assured inside the chamber even when the gas flow change abruptly. (7) The gas distribution plate shall be so designed that any dust or other foreign matter can easily be removed. 5.3.2 Discharge electrode (1) The discharge electrode shall be made of materials featuring good corona discharge characteristics, and strong enough to withstand corrosion or the rapper shock. (2) Appropriate light materials shall be used to that there will not be any large mechanical stress applied to the insulators which support the discharge electrode. 5.3.3

Collecting electrode (1) Appropriate measures shall be taken to prevent the re-dispersion of dust or of the exhaust gas resulting from the rapper. (2) The rapper power shall be delivered evenly to the entire part of the collecting electrode, and shall facilitate the fall of dust. (3) There shall be no thermal strain caused by gas temperature. (4) The materials shall have rust-resistance and mechanical strength against humidity or corrosive gas. (5) There shall be no electric sparks occurring between discharge electrodes.

5.3.4

Rapping system (1) An appropriate number of rapping systems shall be installed on the gas distribution plate, collecting electrodes, and the discharge electrodes. (2) System shall be designed in an appropriate manner so that the overall collecting functions shall not be affected during the rapping cycle.

5.3.5 Support bushing The support bushing shall be made of materials carrying sufficient mechanical strength to support the weight of the discharge electrode, and electrically insulate the high voltage applied to the discharge electrode, with no condensation occurring on the surface. 5.3.6 Key interlock system To protect the system from high voltage during the inspection of the inside the chamber, this system shall be attached to all access doors. The doors shall be so designed that they can be opened even when the high-voltage

6-7

Chapter 6 Dust Collectors

system is shut off and earthed. 5.4 Wet scrubber 5.4.1

The system shall be designed to ensure the dust-containing gas makes perfect contact with the fluid.

5.4.2

The spray nozzle shall be easily replaced with water spraying evenly distributed. The circulating water pipe and nozzle shall use rust-proof materials.

5.4.3

Wet scrubber shall decide the cleaning speed and the liquid to gas ratio according to the properties of the gas, through a separate process of obtaining approval.

5.4.4

Sight glass shall be installed to watch inside the wet scrubber.

5.4.5

As the secondary pollutants, the waste water, occur during the process, the system shall be designed considering the installing a separate waste water disposal system.

5.4.6

As a general rule, cleaning solution shall be selected according to the properties (acid or alkali) of the waste gas, i.e. alkali solution for acid gas, or acid solution for the alkali gas.

5.4.7

A mist remover shall also be installed to prevent the discharge of mist when the processed gas is being discharged.

5.5 Common equipment 5.5.1

Duct, damper and stack (1) Special attention shall be paid to the pipe diameter and the installation location to prevent accumulation of dust inside the duct. (2) The dust moving speed shall be designed to be approximately 20m/sec, through a separate process of obtaining approval. (3) To effectively cope with thermal expansion, expansion joints shall be installed in places considered necessary. (4) To measure the dust concentration and other elements, an inspection opening shall be installed at the front side of the dust collector according to applicable laws; however, such devices shall not interfere with the flow of gas. (5) Damper shall be designed in a structure which will facilitate vertical or horizontal repair or inspection. (6) Stack height shall be decided with an extent that the harmful exhaust gas will not adversely affect adjacent structures and equipment. 5.5.2 Dust conveyors and fans (1) The dust conveyors are classified into a screw conveyor, pneumatic

6-8

Chapter 6 Dust Collectors

(2)

(3)

(4) (5) (6) (7) (8)

(9)

conveyor, and a chain conveyor which is chosen according to dust characteristics and other site situation. The speed of the dust conveyors shall be decided according to the dust characteristics, and rust-proof materials shall be used where abrasion is expected. The dust conveyors shall maintain perfect airtightness even during a long use, and shall be leakage-free even when dust is being conveyed or during unloading work. Of the drive systems, the bearing units shall be totally enclosed to prevent the ingress of dust. To minimize noise and vibration, turbo type fans shall be designed. Anti-abrasion materials shall be used for the fan casing and impeller in consideration of contact with the dust-containing gas. Appropriate type of lagging shall be installed on the stack to reduce noise generated from the fan. The fan casing shall be designed considering the accumulation of water on top, and inspection man holes and drain holes installed to check and prevent air leakage. The speed control shall be classified into a fluid coupling system, electric(VVVF)system, a pole change motor system, and DOR starting system. The type of the control system shall be decided separately based on discussion between KRI and the supplier.

6.0 Fabrication and inspection standards 6.1 Mechanical equipment 6.1.1

This standard shall be prepared to satisfy the design criteria and required performance.

6.1.2

The drive systems shall be delivered in the assembled conditions after completing an independent performance test. If overall fabrication of the drive system is needed due to the site situation, a prior discussion shall be held with KRI.

6.1.3

Similar parts shall be made to maintain compatibility.

6.1.4

Optimal materials of SNI standards or equivalent type shall be used.

6.1.5

If the welding rods are exposed to moisture, cracks may occur on the cover. Store welding rods carefully, and let them dry prior to starting work.

6-9

Chapter 6 Dust Collectors

6.1.6

Brushes or grinders shall be used to remove the slag generated during cutting, and the deformed part resulting from the cutting shall be properly repaired.

6.1.7

Inspection standards covering mechanical systems shall be governed by the provisions of the following KRI inspection standards. (1) Fan : PS-N-05-05 (2) Expansion Joint: PS-N-05-07 (3) dust collector : PS-N-05-12

6.2 Steel structures 6.2.1

Optimal materials of SNI standards or equivalent type shall be used.

6.2.2

Arc welding shall be used. For important members requiring machining, the welded part shall be properly heat treated to remove stress.

6.2.3

Steel structures shall be fabricated according to the basic, detail design drawings and design standards.

6.2.4

The unit of structure that can be transported shall be shop fabricated and assembled as much as possible prior to delivery. For equipment that shall be provisionally fabricated at plant prior to delivery or those to be delivered piece by pie shall require prior discussion with KRI.

6.2.5

For equipment which is likely to be deformed after its fabrication, transporting, and installation, appropriate tools for preventing deformation (jigs) or lifting lugs shall be provided to prevent such deformation or distortion, as needed.

6.2.6

In case of bolts, nuts and fittings used to assemble equipment, spare items shall be provided in addition to the quantities shown on drawings.

6.2.7

The steel structure inspection standards shall be governed by the provisions of the following KRI inspection standards: (1) Steel structure : PS-N-05-17 (2) Painting, and packing: PS-N-05-35 (3) Non-destructive : PS-N-05-36 (4) Hard Facing : PS-N-05-38

6.3 Electrical equipment and instrumentation 6.3.1

The manufacture and inspection standards covering electrical equipment and instrumentation shall satisfy the design criteria.

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Chapter 6 Dust Collectors

6.3.2

The manufacture and inspection standards covering electrical equipment and instrumentation shall be governed by the provisions of the following KRI inspection standards: (1) Transformer : PS-N-05-22 (2) Panel : PS-N-05-24 (3) Cable : PS-N-05-30 (4) Motor: PS-N-05-25

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Chapter 6 Dust Collectors

Attachment 1

Emission Standard

The details of the pollution control norms and the emission standards for various industries are available in the document “Pollution Control Acts, Rules and notification issued thereunder - Central Pollution Control Board”

(Item No. 8) of Annexure-1-1. The information related to Steel and Power

Plant are summarised below:

Thermal Power plant (a) Standard for particulate matter emission

Boiler

Protected Area

Other Area Old Before 1979 New after 1979

Less than 200 MW

150 mg/Nm3

600 mg/Nm3

350 mg/Nm3

200 MW and above

150 mg/Nm3

-

150 mg/Nm3

(b) Standard for sulphur dioxide control (through stack height) Boiler size Stack height H = 14 (Q)0.3

Less than 200 MW 200 MW to less than 500 MW

220 metres

500 MW and more

275 metres

Q = Sulphur Dioxide emission in kg/hr H = Stack height in mtrs

IRON & STEEL PLANT Standard for particulate matter Process

Emission limits

Sintering Plant

150 gm/Nm3

Coke Oven

-

Blast Furnace

-

Steel making

during normal operation

150 mg/Nm3

Steel making

during oxygen lancing

400 mg/Nm3

6-12

Chapter 6 Dust Collectors

6-13

Chapter 7 Electrical Equipment

Chapter 7

Electrical Equipment

7-1

Chapter 7 Electrical Equipment

Table of Contents 1.0

General ...................................................................................................................... 1.1

Scope of application ........................................................................................

5

1.2

Scope of supply ..............................................................................................

5

1.2.1

Range of supply......................................................................................

5

1.2.2

Items out of the range of supply .........................................................

5

1.2.3

Range of supply between machinery makers and electrical equipment makers ...............................................................

1.2.4

Range of supply between electrical equipment at 8

Spare parts ............................................................................................

9

Drawings and documents ...............................................................................

9

Design conditions ..................................................................................................

10

1.3

3.0

6

plant and power receiving and distributing facilities .................. 1.2.5

2.0

5

2.1

General .............................................................................................................

10

2.2

Design standards and regulations ................................................................

10

Engineering services and supervision .................................................................

11

3.1

Engineering services ........................................................................................

11

3.2

Supervision .......................................................................................................

13

4.0

Painting and coloring standards ...........................................................................

14

5.0

Packing standards ....................................................................................................

14

6.0

Design criteria ..........................................................................................................

15

6.1

6.2

General ...............................................................................................................

15

6.1.1

Power system in plant ...........................................................................

15

6.1.2

Arrangement of AC phase and DC polarity......................................

19

6.1.3

Interface among plant facilities, power receiving & distributing facilities and energy center............................................

20

6.1.4

Name plate...............................................................................................

28

6.1.5

Safety ........................................................................................................

30

Voltage standards.............................................................................................

31

7-2

Chapter 7 Electrical Equipment

6.3

6.4

6.2.1

Distribution voltage ..............................................................................

31

6.2.2

Variation of power supply ...................................................................

34

6.2.3

Allowable voltage drop on the line ....................................................

35

Transformer.......................................................................................................

35

6.3.1

General .....................................................................................................

35

6.3.2

Connection method ...............................................................................

37

6.3.3

Rated capacity of transformer ..............................................................

39

Power distribution switchboard ...................................................................

40

6.4.1

General .....................................................................................................

6.4.2

High or extra-high tension enclosed type power distribution board .................................................................................

6.4.3

6.5

6.6

40 45

High tension power distribution board (Combination switch board) ................................................................

47

6.4.4

Low tension power distribution board ..............................................

49

6.4.5

Accessories of power distribution board ...........................................

51

6.4.6

Motor control center ..............................................................................

53

6.4.7

Control system ........................................................................................

61

Rotary machines ...............................................................................................

66

6.5.1

General .....................................................................................................

66

6.5.2

DC motors for rolling mill ...................................................................

71

6.5.3

DC motors for rolling mill auxiliary machine (including crane) ..................................................................................

72

6.5.4

Industrial DC motors ............................................................................

73

6.5.5

3 phase induction motors......................................................................

74

6.5.6

High voltage 3-phase synchronous motors .......................................

76

Electrical equipment for machinery .............................................................

77

6.6.1

Fan and blower .......................................................................................

77

6.6.2

Pump.........................................................................................................

78

6.6.3

Emergency generating equipment for driven diesel engine .........

80

6.6.4

Brake .........................................................................................................

85

6.6.5

Lifting magnet ........................................................................................

86

7-3

Chapter 7 Electrical Equipment

7.0

Construction design criteria ..................................................................................

88

7.1

Lighting ..............................................................................................................

88

7.2

Grounding and explosion-proof facilities ..................................................

99

7.3

Cable ................................................................................................................... 104

7.4

Prevention of electric shock and accidents ................................................. 115 7.4.1

Limitation on exposure to charged parts and on location of electric facilities ...................................................................................... 115

8.0

7.4.2

Limitation on the use of switching apparatus .................................. 117

7.4.3

Danger indication .................................................................................. 118

7.4.4

Plug-socket .............................................................................................. 118

7.4.5

Prevention standard of accident at electric wiring work ................ 118

7.4.6

Fire prevention measures ..................................................................... 120

7.5

Lightning Protection System .......................................................................... 121

7.6

Layout Clearance Safety Requirements ....................................................... 122

Test and inspection standards ............................................................................... 116 8.1

Test and inspection at manufacturing plant ............................................... 116

8.2

Attending inspection ....................................................................................... 116

8.3

Test by authorized organization ................................................................... 117

8.4

Delivery test ...................................................................................................... 117

8.5

Performance test ............................................................................................... 117

8.6

8.5.1

P.A.T ......................................................................................................... 117

8.5.2

F.A.T ......................................................................................................... 118

Manufacturing inspection .............................................................................. 118

7-4

Chapter 7 Electrical Equipment

1.0 General 1.1 Scope of application These standards are applicable to general technical specifications for planning, design, equipment purchase of Electrical equipments for KRI. Detailed technical specifications shall be governed by this chapter. The modification of these standards shall be made with the prior consent of KRIIndonesia in the following cases:

1) In case these standards violate the laws, standards and regulations of Indonesia as well as

International Standards. 2) In case KRI consents with the Supplier’s alternative suggestion, which is superior to these standards. 1.2 Scope of supply 1.2.1

Range of supply (1) Supply conditions and range shall be governed by the provisions of the purchase technical specifications or requirements provided by KRI. (2) As long as there is no special statement on scope of supply, specifications of common application shall conform to the contents of this clause, and general range of supply shall be as the followings:

1.2.2

1)

Designing, manufacturing, inspecting, and transporting the electrical equipment

2)

Engineering services and supervision for installation and operation

3)

Submission of drawings and documents

4)

Performance guarantee and product warranty

Items out of the range of supply (1) Electrical equipment installation work (2) General lighting facilities and architectural electric facilities (fire fighting facilities, etc.) inside of the building. (3) Communication devices (Telephone, Auto Paging and Public Address systems, I-TV) (4) Unloading and storing of delivered goods (5) Instruments, materials and temporary devices necessary to be set up at the site. However, extraordinary devices, which cannot be furnished by KRIIndonesia, shall be exempt. (6) Equipment and materials which shall be necessary for test and operation (7) Leading and execution of commissioning and performance warranty test 7-5

Chapter 7 Electrical Equipment

1.2.3

Range of supply between machinery makers and electrical equipment makers (1) General In principle, range of supply between machinery makers and electrical equipment makers is to be coordinated by the supplier in the supplier group, but for the purpose of smooth handling of troubles, if any, the following range of supply shall be kept in mind by each maker. (2) Range of supply of motors and machinery 1) Coupling

Rough bored half coupling of large size motor shall be supplied by machinery maker. Finishing of the coupling and its key slot shall be completed by electric motor maker. Coupling key shall be manufactured by electric motor maker and cross type key of forged flange coupling shall be manufactured by machinery maker. Supervision of coupling work on site is the responsibility of machinery maker. If the coupling test of motor and machinery is accomplished before shipping, the machinery maker shall be responsible for delivery to the construction site after coupling. Scope of supply shall be provided in accordance with the purchase specification. 2) Common bed

Motors in oil cellar and pump room shall be mounted on a common bed in principle, which shall be supplied by machinery maker. 3) Installation

The installation of small and medium size motors shall be of the scope of installation works and be supervised by machinery maker.

7-6

Chapter 7 Electrical Equipment

(3) Electrical equipment mounted in main body of machine Note. E: Electric maker M: Machinery maker

Classification

Supply of motor, clutch, etc.

Supply of limit switch

Supply of switch box

Processing for Installation

Supply of pipes (for water, oil and air) built in machines

1. Screw down, rolling side guide, etc.

E

E

M

M

M

M

2. Motor driven valve

M

M

M

M

M

M

3. Pressure switch, water level relay, etc.

M

M

M

M

M

4. Detector for automatic operation

M

M

M

M

M

5. Electromagnetic valve

Main body: M

Design of wiring of machinery

Control board: E

Designing of wiring between control board and valves: E

(4) Special unitary equipment, oil cellar, etc. 1) Design, installation and wiring work of electrical devices shall be accomplished by the machinery maker. And, all the electrical equipment shall be the product of a qualified electric machinery maker. 2) Necessary terminals of contact points for integral electrical supervision and alarm shall be attached at the lower end of all electric equipment by machinery maker. (5) Local lighting Design and supply of illuminations attached to machinery shall be within the scope of the machinery maker. (6) Local control box for machinery Local control box shall be supplied by maker of electric devices, and piping and wiring work of electric devices in machinery shall be done by machinery maker. 1.2.4 Range of supply between electrical equipment at plant and power receiving and

7-7

Chapter 7 Electrical Equipment

distributing facilities (1) General If the installation of facilities for power receiving and distributing and electric facilities are performed separately, the supply of them shall follow the below. (2) Plant receiving power of 150KV, 30KV, and 6KV 1) Cable head and flexible terminal shall be included in the power receiving and distributing facilities. 2) Switchboards for receiving power and bus connection in the two circuit power receiving plant shall be remotely indicated in the main power receiving substation. Therefore, necessary specifications of the electric power equipment shall be consulted with power receiving and distributing facilities side. 3) Main motor of rolling mill and major machines in the entire plants shall be interrupted by remote control of energy center or substation, when there an accident happens at electric power source. And the result of the remote break shall be informed to an operator of energy center. 4) Terminal box ① Electric power capacity for control and signal on the items described above shall be limited by terminal box that is near the high voltage switchboard in electric room of the plant. ② Installation and supply of terminal box shall be made by the power receiving and distributing facilities, and each facility side shall suggest the locations of the terminal box. ③ Work scope between power receiving and distributing facilities and plant shall be as followings: Terminal box

transmission Scope of power receiving and distributing facilities

Each Plant Scope

Scope00 ④ Terminal box for power receiving and distributing facilities and

for plant facilities shall be installed separately. (3) Telephones for general service and simultaneous communication equipment

1) Telephones, amplifiers and speakers used for power receiving and distributing facilities shall be supplied by the power receiving and distributing facilities. (4) Road lighting

Streetlights of main roads shall be included in facilities of power receiving and distributing, and lighting around plant shall be included in the interplant facilities.

7-8

Chapter 7 Electrical Equipment

1.2.5 Spare parts The supplier shall provide a list of spare parts for 2 years operation and consumables of the supplied facilities and equipment. The items and quantities of spare parts shall be determined through mutual agreement between KRI and the supplier. 1.3

Drawings and documents The general contents about drawings and documents shall comply with Part 2, ISZ-1 and the following items shall be added in the part of electric facilities. (1) Load (Motor, TR) list (Equipment name, application, rated capacity, etc.) (2) Sensor list (Type and operation principles shall be described) (3) List of electric devices (Kinds, type, application, structure, etc.) (4) Single line diagram (5) Entire system diagram (System configuration or wiring block diagram) (6) Internal connection diagram (7) Out-line drawing and installation drawing (8) Wiring system diagram (Kinds of cable and its size shall be described.) (9) Internal terminals connection diagram (10) Manual for sequence operation (11) Manual for sequence analysis and procedure (Symbols, etc.) (12) Shop test and inspection test reports (Integral test, individual test, characteristic

curve, standard applied, etc.) (13) Report for test, operation, adjustment and inspection (14) Documents to be submitted to government or public organization (15) Intake hole size (16) Technical data and catalogue (Voltage drop allowance, protective system cooperation,

capacity of harmonics generated, etc.) (17) Other details shall be discussed with KRI.

7-9

Chapter 7 Electrical Equipment

2.0 Design conditions 2.1 General The weather and geographical conditions for the area where equipment are installed shall meet the Part 4 Design conditions, ISZ-1. 2.2 Design standards and regulations 2.2.1 Items not described in this standard shall follow the laws and regulations described below. Also, separate guide for the data, documents and drawings that will be submitted to the government office based on electric enterprise shall be provided (1) The electric enterprise law, the government executive ordinance and the

ministerial executive ordinance pertaining to the same (2) The technical standards of electrical equipment and the notification

pertaining to the same (3) Administrative law of electric power technology (4) Laws for prevention and extinction of fires, and their enforcement

regulations (5) Building standard law and its enforcement regulations (6) Labor law and its enforcement regulations (7) Law of radio wave control and its enforcement regulations (8) Law of safety supervision for electric appliance and its enforcement

regulations 2.2.2 International related regulations and Standards like IEC, ISO and each country’s industrial regulations of SNI, PUIL, KS, JEC, JEM, NEMA, etc. shall be applied.

7-10

Chapter 7 Electrical Equipment

3.0 Engineering services and supervision 3.1 Engineering services Commonly applicable conditions shall follow Part 3 Engineering ISZ-1. The details shall be the following. 3.1.1

Basic design (BD) The work classification for basic design shall follow Paragraph 2.1.1 of Part 3, ISZ-1.

3.1.2

Detail design (DD) The work classification for detail design shall follow Paragraph 2.1.2 of Part 3, ISZ-1.

3.1.3

Installation design It indicates a design concerned deals with installing electric devices. It is included in detail design. (1)

Definition of installation design 1) Design of electric equipment of plant

Design of wiring and supplier's device setup Design of local lighting for special place Installation design of ITV Cabling design for power supply to each facility like trolley and welder 2) Internal wiring distribution design for machinery

Cabling design for devices in single-unit like crane or lathe, etc. Illumination design for inside and outside of machinery 3) Installation design for communication system of inside plant

Installation design for telephone, local broadcasting system and cable 4) Illumination design in inner plant

Illumination design for inner plant building Illumination design for plant’s surroundings 5) Electric design for general construction facilities

Electric design for control center, sub-center and equipment room 6) Design for external wiring distribution 7-11

Chapter 7 Electrical Equipment

Design of power cables among plants and remote supervision and control cables for power receiving and distributing facilities (2) Supply classification for installation design --- > Should be clarified

later KRIIndonesia

Classification

Supplier

Design of electric facilities for plant

○

Design of internal wiring distribution for machinery

○

Design of installation for communication system inside plant

Note Include installation for a lighting rod and aircraft interference light

○

Local telephones

Design of illumination facilities for inside plant

○

BD shall only be done by the supplier. -- > All illuminations level should be provided by KRI – Indonesia

Electric design for construction facilities

○

Design of external wiring distribution

○

(3)

Design area for electrical facilities of plant 1) Lay Out Design

-

Layout Plan

-

Cross-sectional

2) Data for civil engineering and construction drawing

-

Ground digging data

-

Plan for bolting

-

Construction data (At a maximum value of unit that is carried into plant)

-

Data of large rack and large air duct for cabling or air duct for laying under the ground.

7-12

Chapter 7 Electrical Equipment

3) Design for electric system

- Design for electric system - Design for system protection and cooperation - Design for air duct, supplying water, drain and grease system 4) Design of electric facilities’ installation - Guide for cabling - List of installation materials (List that is classified according to the scope of supply) 5) Design of cabling - Design of cabling route - Design of duct and rack - Design of cables (including extra line supply) - Cabling schedule - Interface - Work design for cabling - Guide about grounding - List of installation materials (List that is classified according to the scope of supply) 6) Design for local illumination - Design for luminous intensity - The selection, arrangement and installation method of illumination facilities - Wiring design - List of installation materials (List that is classified according to the scope of supply) (4) Design scope of machinery’s internal wiring distribution 1) Design of electric system: Same with the design of electric facilities in plant described above 2) Design of electric cable: Same with the design of electric facilities in plant described above (5) Design scope of external wiring distribution 1) Design of cable route: Electric conduits, trough, manhole, hand hole and list of installation material 2) Design method: Method of arrangement, connection and cable head management 3.2 Supervision Supervision shall be governed by the provisions of Paragraph 3 2.2, ISZ-1.

7-13

Chapter 7 Electrical Equipment

4.0 Painting and coloring standards Painting and coloring application shall be governed by the provisions of Part 5 Painting ·coloring · packing, ISZ-1. 5.0 Packing standards Packing application shall be governed by the provisions of Part 5 Painting ·coloring · packing, ISZ-1.

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Chapter 7 Electrical Equipment

6.0 Design criteria It shall be applied to basic and detail design according to Paragraph 2.2 Design standard and regulation. 6.1 General 6.1.1 Power system in plant The main principles of power system in plant are discussed here. (1) High and Medium voltage circuit system

Classification

30kV circuits

6kV circuits

1. System

AC 3 phase 3 wire type

AC 3phase 3 wire type

2. Grounding method for neutral

100A Resistor grounding

100A Resistor grounding -- > Solidly Grounded

3. System method

Loop method or tree branch method

Loop method or tree branch method

4. Cable branching

Not permitted on the line

Not permitted on the line

(1) Feeder

Circuit breaker

Circuit breaker

(2) Load, TR

Circuit breaker

Circuit breaker or Combination Switch

(3) Transformer for operation and meter

Current Limiting Fuse or MCCB with alarm

Current Limiting Fuse or MCCB with alarm

(1) Protection for overload and short circuit

Over Current Relay (OCR)

Over Current Relay (OCR) Combination switch : OCR or MPR

(2) Protection for ground fault

Over Current Grounding Relay (OCGR)

Over Current Grounding Relay (OCGR)

(3) Protection for under voltage

Under Voltage Relay (UVR)

Under Voltage Relay (UVR)

5. Switching equipment

6. Protecting method

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Chapter 7 Electrical Equipment

Classification 7. Minimum Cable Size

30kV circuits

6kV circuits

120 mm2

70 mm2

(However, the size shall be based on short current calculation.)

(However, the size shall be based on short current calculation.)

(Calculation form) Is * √t A = --------------141

Is * √t A = --------------92.7

for copper conductor

for Aluminum conductor

SNI : Short Circuit Current(kA)

A : Cross Section of Cable(㎟) t : Duration Time of short Circuit(sec) 1) The actual Short Circuit Current should be applied to “SNI”. ① When the receiving voltage is same as sub-station voltage , “SNI” is calculated from the substation impedance and receiving line impedance ② When using down transformer, transformer impedance is added to ① 2) The following shall be the standard duration time of short circuit. It is adjusted according to the system protection characteristics. - Circuit breaker feeder: 0.3sec - Combination switch feeder :0.05sec 3) When choosing the minimum size cable , 3C cable is given the priority. Note

1) OCR shall include instantaneous elements if the feeder is an independent load. 2) Cable size shall be applied to copper conductor cable.

7-16

Chapter 7 Electrical Equipment

(2) Low voltage circuit

Classification

380V

220V

220/110V 220V

1. Circuit System

AC 3 phase 3 wire

AC 3 phase 3 wire or single phase 2 wire

AC single phase and 2 3 wire

2. Grounding method

Ungrounding or resistance grounding

Ungrounding or resistance grounding

Ungrounding or resistance grounding Solidly Grounded

3. Power source and its application

30kV, 6kV/380V/220V

6kV

6kV or /380V

220V

(used Delta-Wye Transformer), 3phase, 4wires for lighting

For sub center lighting

415V

6kV 380V/

220V

110V For instrumentation 380V For motor

For control circuit

220V For control circuit

220V

30kV,

110V

6kV 380V/

220V

For repair or lighting

7-17

For instrumentation

Chapter 7 Electrical Equipment

Classification

380V

4. System method

220V

220/110V

Tree branch type

Tree branch type

Tree branch type

(1) Protection for overload and short circuit

ACB or MCCB

MCCB

MCCB

(2) Protection for ground fault

Incomer : Over Current Ground with Alarm device (Alarm) Each feeder : Directional Ground Relay (DGR)

MCB

Same as the left

5. Protection method

(Miniature circuit breaker shall be installed at lighting/socket)

Feeder for maintenance : Earth leakage circuit breaker to prevent shock (3) Power source for repair 1) Power source for welder or portable tools: AC 3 phase 220380V, 4 wires 2) Earth leakage circuit breakers shall be installed in the repair source box

for portable tools.

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Chapter 7 Electrical Equipment

6.1.2 Arrangement of AC phase and DC polarity (1) The arrangement of conductor and equipment in AC distribution panel is

as follows. 1)

Apparatus or testing terminals shall be shown from the operating side.

2) Connection of the main circuit shall be arranged as following to be

seen from operating side of the main switch. ① The arrangement of phases Direction Left to right

Top to bottom

Near place to far place

3 phase

Red, Yellow, Black, (Blue =N)

Red, Yellow, Black, (Blue =N)

Red, Yellow, Black, (Blue =N)

Single phase

Red, (Blue = N), YellowGreen

Red, (Blue = N), YellowGreen

Red, (Blue = N), YellowGreen

P,N

P,N

P,N

Current

AC

DC

Note) (N) is applied when there is a neutral phase.

② The color of apparatus and conductor 3 phase circuit

Single phase circuit

DC

R (Red)

Positive pole (Red)

N (Blue)

Negative pole (Black)

R (Red) Y (Yellow) B (Black) PE (Yellow-Green) N (Blue) Note) The color of grounding wire shall be yellow-green.

(2) Color and insulation for high voltage and 380V Main Bus

High voltage bus above than 380V shall be taped with vinyl tapes of Paragraph 6.1.2 ②(Red, Yellow, Black). As the bus installed out of the panel can't be colored entirely, it shall be colored by 10 cm-wide tape in every 1 m.

7-19

Chapter 7 Electrical Equipment

6.1.3 Interface among plant facilities, power receiving & distributing facilities and energy center (1) Interface between plant facilities and power of receiving and distributing

facilities (remote supervision, control and pilot wire)

No

1

Subject

Working scope of each plant

Protection - CT for pilot wire shall circuit with be installed at plant side pilot wire (2 and be connected to terminal box. lines power receiving plant This CT shall be and 150kV installed at the primary power receiving side of power receiving plant) transformer. (BCT) - Trip circuit of secondary Circuit Breaker shall be connected to terminal box so that the secondary CB can be disconnected by PW Ry signal.

Working scope of power receiving and distributing facilities - Supply and installation of pilot wire relay panel (including transmission system) and connection of cable from terminal box to substation

2

Remote - Related plants are those supervision for receiving power above 30kV. circuit breaker’s On/Off state. - No-voltage a, b contact of corresponding CB shall be wired to terminal box.

- On/Off indication of CB that is indicated at the left cell.

3

Supervision of transformer’s fault

- Heavy fault of TR shall be indicated and warned. And the feeder CB shall be tripped through transmission device.

- Power receiving transformer of main plants shall be the working scope. - All the contact points for heavy and light fault of the above transformer shall be wired to terminal box.

7-20

- Indication of light fault of TR.

Remarks

Ratio & characteristics of CT for pilot wire shall be the same as those of Power Receiving & Distributing Facilities.

- Heavy fault means 96, 63, 87 and 51N relay’s operation. - Light fault includes temperature rising and decline of oil level.

Chapter 7 Electrical Equipment

Working scope of each plant

No

Subject

4

Load limitation of each plant

Load shall be limited by the trip signal of power receiving and distributing facilities through terminal box and re-starting of load shall be locked until receiving “OK” signal.

5

Preventing misoperation of incoming DS

- Interlock system shall be installed both of the 30kV incoming DS and load side CB.

Working scope of power receiving and distributing facilities

Remarks

- Installation of load limitation devices and cable connection to substation.

30kV incoming DS shall be turned On of OFF only when CB of load side is OFF. - To achieve the above purpose, pilot lamp(ON/OFF) and interlock nameplate shall be installed at 30kV panel. 6

Hot-line (To communicate with power receiving and distributing facilities)

- After discussing with PRDF, location of electric rooms where direct telephone shall be placed and quantity of direct telephone shall be determined, and connection shall be made at the terminal box.

7-21

- Auto-exchange type direct telephone amplifier shall be installed.

- Places or posts for rolling mill load limitation warning and communica tion shall be fully understood.

Chapter 7 Electrical Equipment

No 7

Working scope of each plant

Subject Others

Working scope of power receiving and distributing facilities

Remarks

- Under voltage relay shall not be applied independently to 6kV/380V, 6kV/220V transformer that is used as power or lighting - Instantaneous element of “27” relay shall not be applied to 6kV motor. Combination switch shall be of delay release type(0.5sec) - Grounding protection of 30kV, 6kV feeder and loads ……….. OCGR + OVGR : If CT ratio exceeds 400/5, ground current shall be detected by tertiary winding. : 30kV, 6kV system shall be grounded to 100A grounding system (per TR 1 Bank) -

Grounding protection of 380V feeder ……………. : DGR(67G) +OVGR (for warning circuit)

(2)

Interface between plant facilities and energy Center (Including environmental monitoring center and fire prevention center) 1) Transmission signals to energy center Energy center facilities shall manage the various utilities and operation of major equipment for each plant and all facilities. Therefore, the following signals shall be transmitted to energy center from each plant and all facilities: ①

Utility signal produced and consumed at each plant and all facilities. - Power, gas, oil, steam, hot water, clean and fresh water, seawater, oxygen, nitrogen, argon, hydrogen, compressed air, etc. - Pressure, temperature, water level in the tank and velocity signals of gas, oil, steam, hot water, etc.

② Signal of operation status of main equipment of each plant and all facilities - Furnace, main blower, main rolling mills, compressor of oxygen plant, converter, Kiln, continuous casting machine, generator, Boiler, gas facilities, water facilities, dust collector and fire prevention equipment ③ If equipment that is managed by energy center is installed, utilities for the equipment shall be included in the plant design. - Local station, relay, transducer panel, etc.: 220V or 110V AC - Environmental measuring facility: Instrumentation Air (Dry Air), clean water and 220V or 110V AC

7-22

Chapter 7 Electrical Equipment

2) Method of signal connection

① Signals shall be connected to terminal box (E/C), panel for TM/TC cubicle or transducer panel. ② Connection type a. Analog and contact signal (A type) b. Signal that is used for TM/TC (B type) Type

Connection method

Note

A

TM/TC

B

TM/TC

* TM/TC: Tele Metering/Tele Control

7-23

Chapter 7 Electrical Equipment

③ Signal specification a. Signals transmitted to E/C from other facilities Signals

Condition

Remarks

Kinds of signal:

Analog signal

Contact signal

Pulse signal

-

Insulated 4 ~ 20mA DC

-

Linear signal

-

Resistance value of maximum allowable load: 600Ωor more

-

Contact that is not with voltage

-

Contact rating: 110V DC, 50mA or more and be kept on for 250ms or more

-

Contact without voltage

-

Pulse width: 50ms or more

-

Pulse interval: 2.5sec or more

b. Signal transmitted to other facilities from E/C Transmission signals

Condition

Remarks

Kinds of signal: Insulated 4 ~ 20mA DC Analog signal Resistance value of maximum input : 300Ωor less Contact without voltage Contact signal Contact rating: 110V DC, 1A or more It shall be kept on for 1sec or more.

7-24

TC equipment output

Chapter 7 Electrical Equipment

c. Common connection method of contact signal (a) Connection in T.B or transducer panel

When connecting the TM/TC equipment, one common contact shall be placed among 10 contact points.

TM/TC Equipment

(b)

7-25

Chapter 7 Electrical Equipment

3) Wiring

① Wiring in E/C terminal blocks

② Cable specification a. Kinds of cable: b. Conductor size Strand cable: more than 2.5mm2 Single-core cable: less than 1.5 mm2 ③ Connection of distribution lines in transducer panel a. "Block" terminals shall be used. b. Cables’ specification is as follows (a) Kinds of cables: (b) Conductor size ○

Strand cable: less than 6 mm2

○

Single-core cable: less than 4 mm2

7-26

Chapter 7 Electrical Equipment

4) Materials for construction

Classification

Main signal cable

(Facilities supply)

(Design/materials)

E/C supply

Inside of plant or facilities (Design/materials)

Electric rooms of plant and facilities side (Design/materials) ○

○

(T.B)

Facilities or plant supply

○

○

(Cable Route &

(Layout for installation of terminal box)

Trough or Pit)

7-27

Chapter 7 Electrical Equipment

6.1.4 Name plate (1) The name plate of electric facilities shall be made of anti-corrosive copper

plate or equivalent metal or plastic, and be attached to a place easy to be seen. (2) The symbol and major specification of the electric machinery shall be

written on the name plate. (3) To all rotating machines except cooling fan, the name plate such as the

following figure shall be attached. (4) All letters of the name plates shall be written in English. (5) The name plate of DS and CB

The name plate (made of acryl) of DS, CB shall be attached below the red-green pilot lamp on the panel with the following specification. 1)

The size of name plate: 3 ㎜×55 ㎜×90 ㎜. It shall be inserted from top to bottom.

2) The lower part of name plate shall be located 3~5 cm apart from the

upper part of CS. In case of DS panel, name plate shall be located 8~10 cm apart from the lower part of red-green lamp. Note) 1. 2.

The number applied to supervisory and operating panel shall be carved together with its name. All the number of CB, DS shall be determined after discussing with KRI.

7-28

Chapter 7 Electrical Equipment

65

(1) Outline: black with yellow

background. (2) Thickness: 1mm (3) Brass or stainless steel plate (4) Size of letter: 6.3mm (5) All characters shall be

engraved in black.

3ΦHOLE x 4

Name plate types for rotating machines

Classification

AC

AC 380V

DC

Symbol

Capacity

Pole

Maker

(1)

(2)

(3)

(4)

11,000V

A

2

6,000V

B

4

3,300V

C

6

Squirrelcage type

D

6

Wound rotor type

E

Others

F

Generator

G

12

Motor

M

14

Others

Z

Not applied to DC

Indicated in the unit of kW

Manufacturing date (5)

Ident.No (6)

8 10

Note) Type of name plate over other ones or class of voltage shall be decided after mutual agreement.

7-29

Chapter 7 Electrical Equipment

6.1.5 Safety (1) In case of power or water failure, it shall be considered carefully to be

seriously damaged. (2) General considerations

1) Power failure: 30kV system: maximum 5 hours 2) Faults on electric machines: Important facilities like oil pump shall not be damaged by any faults of the electric system. For example, 1 set of oil pump in normal operation (AC driven) shall be equipped with 1 set of oil pump driven by battery for standby. 3) Fire

①

For fire detectors, method of early detecting and early fire extinguishing shall be considered. a.

Temperature relay, instantaneous pressure relay shall be installed in important facilities with a large capacity for early detection of temperature rising, oil bursting, etc.

b.

Fire and smoke detector shall be installed in oil cellars and electric cellars, etc.

② Fire fighting facilities Automatic fire fighting facilities shall be included in important facilities. It shall be included in purchase specification. (Oil cellar and generator in power station) KRI shall provide fire-fighting facilities for general electric facilities. ③ Preventing the spread of fire a. Transformer In case of transformers of 220kV and 150kV, insulating oil outflow prevention facilities shall be installed to prevent insulating oil flowing out debouchment and seeping into the underground. b. Cabling - Cabling affected by external heat shall be protected and covered by excellent heat resistant materials. - Power cables and control cables shall be isolated by using different ducts or by using separators in case the two kinds of cables are laid in the same duct. - In places of high temperature or places affected by the external heat, excellent heat-resistant cables shall be used.

7-30

Chapter 7 Electrical Equipment

6.2 Voltage standards 6.2.1 Distribution voltage (1) Distributing voltage shall be based on as following table: Distribution Voltage

AC

DC

Application

150kV

Incoming Voltage, Main Transformer

30kV

Power Transformer for rectifier

11kV

Large Motor

6kV

High voltage motor, Transformer for rectifier

380V

Low voltage motor(not more than 150kW), Rectifier

220V

Lighting, Portable motorized tools, Sockets

110220V

Control Power Source

750V, 1200V

Rolling motors in the plant

380V

Variable voltage D.C. motors

220V

Constant voltage D.C. motors in the plant

110220V

Control Source for EHT, HT, LT Switchgear

For small scale lighting like sub-center, etc., the electrical system shall be single phase, 3 wire, 220/110V. Since the minimum voltage that is supplied to plant is 380V, a necessary step-down transformer for instrumentation facilities shall be installed to satisfy instrumentation facilities. In case there is not any 380V power source supplied, single-phase 220V is available as a power source.

(2) Rated voltage of AC generator

50Hz 11,000V 380V(220V)

Remarks Steam turbine generator Movable tools for emergency stationary construction

7-31

Chapter 7 Electrical Equipment

(3) Rated voltage for motor

AC (50Hz)

DC

Remarks

1,200V

11,000V

750V

6,000V

600V

380V

380V

220V

220V

(4) Voltage of transformer and rated voltage 1) Step-up transformer for the voltage of generator to extra high voltage

or high voltage Rated primary voltage (V)

Rated secondary voltage (V)

Tap voltage throughout the full capacity (kV) (Secondary winding)

30,000

± 2 x 5%

150,000

± 2 x 2.5%

150,000

± 2 x 2.5%

6,000

11,000

2) Transformer for extra high voltage to the other extra high voltage or

high voltage Rated primary voltage (V)

Tap voltage throughout the full capacity (V) Rated secondary voltage (V) (Primary winding)

150,000

±9 x 1.25%

30,000

220,000

±9 x 1.25%

150,000

7-32

Chapter 7 Electrical Equipment

3) Transformer for extra high voltage to the other high voltage

Rated primary voltage (V)

Tap voltage throughout the full capacity (V) Rated secondary voltage (V) (Primary winding)

30,000

± 2 x 5%

6,900 / 11,000 400

11,000

± 2 x 5%

6,900 / 435400

4) Transformer for high voltage to low voltage (to be clarified later)

Tap voltage (V) Rated primary voltage (V)

6,300

(Primary winding) Tap voltage throughout the full capacity 6,900

6,000

Tap voltage at reduced capacity 6,000 5,700

Rated secondary voltage (V)

115 230 435 400

Note) Secondary voltage of transformer for rectifier may be chosen as desired.

5) Transformer transforming low voltage to the other lower voltage Tap voltage (V) Rated primary voltage (V)

(Primary winding) Tap voltage throughout the full capacity

Tap voltage at reduced capacity

Rated secondary voltage (V)

210

230

220

200

190

115

405

445

415

385

365

215

7-33

Chapter 7 Electrical Equipment

6.2.2

Variation of power supply Electric machinery and wiring shall be designed to consider the following condition of Voltage and Frequency (1) Voltage variation during normal operation

: - 10% ~ +5% at 150kV (2) Frequency variation : ± 6% at 50Hz (3) Voltage drop during motor starting At the connected bus, the voltage drop during motor starting shall be designed as follows: 6kV systems

: 5% and below

380V system

: 10% and below

(4) Permissible flickering rate 1) Application : Plants where electric furnaces are newly installed or increased 2) Value of permissible flickering rate On the basis of bus in power taking over substation, value of permissible F·R shall be below 2.5% represented by the maximum voltage drop ratio in case of calculating the predictions, and below 0.45%[V] (1 hour average value) represented by △V10 in case of actual measuring. (5) Permissible value of Harmonic 1) Application: Plants where power conversion equipment that generate and supply harmonics are newly installed or increased 2) Permissible standard value

Total Harmonic Voltage Distortion (THD) value shall be less than 3% at 30kV or below, and shall be less than 1.5% at 150KV or above.

7-34

Chapter 7 Electrical Equipment

6.2.3

Allowable voltage drop on the line (1) The allowable voltage drop in each feeder and branch line is not greater

than 2% of standard voltage. (2) The voltage drop of low voltage can be applied as following table. The

“Length of Wire” in the table is the distance between the secondary2’ry terminal of power supplying transformer and the farthest load

Length of line

Voltage drop (not greater than) Tr. & Load are in the Tr. & Load are not in the same plant same plant

0~ 120m

5%

4%

~ 200m

6%

5%

longer than 200m

7%

6%

Notes: due to the Indonesian Standard (PUIL) the maximum voltage drop should be 5% 6.3 Transformer 6.3.1

General (1) In principle, a dry type or molded type transformer shall be used, if the primary voltage of transformer installed indoors is below 6,000V. Supporting structure for cable and bus bar shall be installed in the setting panel. (2) Insulation oil In case of oil-immersed type, adequate insulation oil shall be used according to IEC 60296. (3) Accessories 1) The fault-contact prevention plate shall be installed in the transformer that transforms extra high or high voltage to low voltage and shall be connected to external terminal. 2) Winding temperature measuring device (indirect method is available) shall be equipped in the transformer whose primary voltage is higher than 17kV. 3) Thermometer with alarm contact shall be attached to transformers of more than 750KVA. 4) Nitrogen sealing device or diaphragm type conservator, instantaneous pressure relay or the equivalent, and No Load voltage Tap Changer (NLTC) shall be attached to transformers with capacity of 1000KVA or more. 5) In case of 2000KVA or more, stop valve shall be attached separately to body of the upper and the lower connecting position of thermal body and the radiator.

7-35

Chapter 7 Electrical Equipment

6) In case of self-cooling type of 5,000KVA or more, transformer shall be designed to be able to attach air-cooling fan to it. (4) Others 1) Insulation level of bushing shall be as follows. 6kV : 6A 10kV : 10A 20kV : 20A 60kV : 60A Please clarify about unit of “A” (i.e. 6A for 6kV) 2) Insulating transformers shall be used for lighting transformers and control transformers. 3) Power transformers shall be subtractive polarity. 4) Inspection window shall be installed to inspect the internal bus connection status of terminal box. 5) In case the primary voltage is 6kV11kV or more, bushing type CT (primary, secondary, neutral point: necessary) and percentage differential relay (87) shall be installed.

7-36

Chapter 7 Electrical Equipment

6.3.2

Connection method (1) Power transformer

Voltage

Connection

Ground

Direct ground,

1 wire ground fault current

LA

Similar to short

Resistance

100A

150,000V

Grounding equipment

190Ω, 30sec resistor:30kV 30,000V

63.5Ω,

6,000V

Resistance

100A

Ungrounded

Contact preventive plate shall be installed and shall be grounded with 2nd class.

380V Resistance

39.8Ω, 30sec resitor:6kV

10A

Ungrounded 220V and 110V

Solidly Grounded

(2) Transformer for illumination and repairing 33/11kV 220V Contact preventive plate shall be 6kV attached except that the primary voltage is 380V. 380V

100Ω (Metallic resistance: 1A continuous rating)

(3) Transformer for control circuit 33/11kV 6kV/ 380V

220V

7-37

Contact preventive plate shall be attached except that the primary voltage is 380V. (Metallic resistance: 1A continuous rating)

Chapter 7 Electrical Equipment

30KV

150KV

380V

Note) Exclusive transformer for extension light shall be installed at blast furnace, rolling mill plants, mould repair shop and working places where electric shock may easily occur due to high temperature and humidity. Extension light's voltage to ground shall be lower than 50V.

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Chapter 7 Electrical Equipment

6.3.3

Rated capacity of transformer Rated capacity of transformer shall be indicated by KVA. The standard of rated capacity of the transformer within 1KVA and 30,000KVA shall conform to the following table: (1) Single phase transformers Unit: KVA Standard capacity 10 100 (15) 150 20 (3)

200 30

5

300 50

(7.5)

500 75

(2) 3 phase transformers Unit :KVA Standard capacity 10

100

1,000

10,000

(15)

150

1,500

15,000

20

200

2,000

20,000

30

300

3,000

30,000

(3) 4,500 5 50

500 6,000

(7.5) 75

Note)

750

7,500

In case forced cooling devices are attached, it shall be able to operate at 125% continuous overload.

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Chapter 7 Electrical Equipment

6.4 Power distribution board 6.4.1 General (1) It shall be applied to enclosed switchboards, high-voltage combination

switchboards, low-voltage switchboards, and control panels and operating desks. (2) Related standards (It shall be modified as per the IEC standards code.)

JEM-1425

: High-voltage enclosed switchboard (3.3-30kV)

JEM-1225

: High-voltage Combination Starters

JEM-1265

: Low-voltage enclosed switchboard

JEM-1167

: High-voltage AC electromagnetic contactor

JEM-1021

: Insulation resistance and enduring voltage of control apparatus

JEM-1293

: Low-voltage current limiting fuse

JEM-1136

: Bus for switchboard

JEM-1134

: Arrangement of devices and conductors and their colors according to AC phase and DC polarity : Rating of switchboard

JEM-1254 JEM-1267

: Kind of protective structures of switchboard control system

JEM-1321

: Test of switchboard

JEC - 160

: Air circuit breaker

JEC - 2300

: AC circuit breaker

JEC - 1990

: Disconnecting switch

JEC - 2330

: Power fuse

KS-C-4611

: High voltage AC circuit breaker

KS-C-4620

: Cubicle type high voltage power receiving facilities

KS-C-4612

: High-voltage current limiting fuse

KS-C-8321

: Circuit breaker for wiring

KS-C-4613

: Earth leakage circuit breaker

IEC 947-1

:

Low voltage Switchgear and control gear

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Chapter 7 Electrical Equipment

(3) Power source for control 1) Selection of voltage

① Control voltage of electric facilities shall be as following table: DC Classification

AC (50Hz)

Operated by battery

Operated by rectifier

Breaker

110V

110V

220V

Protective circuit for power control circuit

110V

110V

220V (or 110V)

DC Magnetic Contact

110V

220V

AC Magnetic Contact

110V

220V

220V or 380V

Magnetic Brake

110V

220V

220V or 380V

Magnetic Valve

110V

24V

110V

Note)

Compensating ratio (5~10%) of supply voltage shall be taken into consideration when designing. Example) 115 ~ 120V for 110V 230 ~ 240V for 220V ② As DC source voltage is 220V, DC magnetic contact shall be DC 220V. ③ In case magnetic contactor is operated by rectified power source, DC 220V, this DC power shall be applied to the magnetic brake, too. ④ Frequently operated valve shall be controlled by DC. In this case, DC 24 V or AC 110V system shall be applied. ⑤ DC power source for control shall be equipped with ground fault detecting devices.

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Chapter 7 Electrical Equipment

2) Storage battery

① Application As a power source for operating circuit breaker and control, the storage battery shall follow the below standards. ② Specification a. Type: Dust proof cubicle type, made of steel plate. (a) If cubicle type storage battery is unavailable due to large capacity, stationary type shall be applied. (b) Alkali battery cell jar shall be transparent so that the liquid level can be seen. b. Battery charger voltage: Output: DC 110V Input:

AC 3-phase 380V, 50Hz

c. Capacity: The calculation sheet shall be submitted by the maker. d. Specification of storage battery Enclosed type alkali: Ni-Cd Enclosed type Lead Acid Battery: Sealed Maintenance Free

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Chapter 7 Electrical Equipment

(4) Protective relaying

Digital protective relays shall be applied if necessary. Protective relay system for AC circuits shall be based on the following: Object to be protective 30kV Feeder, and load

Protective relay Short: OCR + (UVR) Ground short: OCGR + OVGR Short: OCR + (UVR)

Ground short: OCGR + OVGR 33(11) kV class Transformer protection: Differential protective relay (87) transformers When 87, 51N and TR heavy fault occurs, primary and secondary circuit breakers shall be tripped. Circuit breaker -

Short: OCR

Ground short: OCGR + OVGR 6kV feeder and load

Combination Switch - Short: High voltage current limiting Fuse (Overload: OCR or MPR) Ground short: OCGR (3E relay shall not be applied to thyristor load.) Short: Protecting devices for overload

380V feeder load

Ground short: OVGR + DGR (Earth leakage breaker for movable tool) Short: Protecting devices for overload

220V Feeder Ground short: Earth leakage breaker for movable tool, etc.

Example.

Ground short protective system for 380V 6kV/380V transformer with contact protective plate

Note)

1. In principle it shall not be tripped by ground fault. 2. GPT and ground over-voltage relay shall be installed. 3. If ground fault occurs, after detecting with 67 relay and displaying the target, buzzer will be run. Buzzers shall be installed both in central operating room and supervision room. After consulting, the place for fault circuit indicator shall be decided.

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Chapter 7 Electrical Equipment

6.4.2

High or extra-high tension enclosed type power distribution board. (1)

General Vacuum or gas insulated switch gear type shall be adopted.

(2) Type: Vertical self-standing metal clad, dust proof type switchboard for

indoor or outdoor use. Box protecting class IP54 of IEC-529 shall be applied for outdoors. (3)

Structure 1) Grade above the MW or MWG classified by JEM 1425 shall be used. 2) Swing doors with locking devices in front and rear side of panels shall be prepared, and circuit breaker shall be able to be drawn out from the front of panel. Control circuits shall be connected with multiple plugs. 3) The number of piling-up shelves for a circuit breaker shall be 2 or less. 4) The space of cable head shall be wide enough to facilitate cable end treatment, maintenance and inspection. 5) CV/XLPE cable shall be used. Bracket for cable head piling up shall be installed. 6) The power source shall be connected to DS clip side and loaded on blade hinge clip side. 7) Panels shall be considered to prevent rats from entering inside of panels. Split Bakelite plate or aluminum plate shall be attached to the bottom of the panel in order to drill holes suitable for cable entering. 8) If necessary, door interlock shall be installed on each panel.

9) When the circuit breaker is drawn out MW class panel, disconnecting part shall be automatically separated from control and bus parts by insulating shutter so that it doesn’t contact to hot line of bus. 10) In case of 2 storey panels, laying and connecting cables shall be carried without turning off the power of other panels. A barrier shall be installed between upper and lower parts. 11) Metallic wall, metallic net or acrylic plate shall be installed to prevent people from touching the live part, opening panel door. Moreover, these protecting devices shall not be easily removed. 12) Signal lamps which indicate the status of power shall be installed on the front and back door of panel. (4) Bus system 3 phase 3 wires Single bus or Double bus (5) Rated current of bus: To be decided by maker or by KRI

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Chapter 7 Electrical Equipment

(6) Rated circuit voltage

30kV, 6kV (7) Insulation class ( As per IEC Standards, it shall be modified.)

30kV: No. 30A, 11.5kV: No. 10A, 6.9kV: No. 6A (8) Breaking capacity of piling up break 1) Breaking facility of break shall be as follows. Nominal voltage of circuit (kV)

Rated voltage of circuit breaker (kV)

Rated symmetric breaking capacity of circuit breaker (kA)

6.6

7.2

25, 31.5, 40,

11

12

31.5, 40, 50

33

36

25, 31.5, 40, 50

132

145

31.5, 40

220

245

40, 50

2)

Even if rated breaking current flows through the circuit breaker for 2 second, the circuit breaker with a voltage of 6kV or higher shall maintain its performance. (Including bus) Breaking capacity of a circuit breaker shall be determined after system calculation. Note : When 2 sets of 30kV/6.9 kV transformers are operated with parallel by way of bus-tie, breaking capacity of CB of the secondary transformer, bus tie and each feeder shall be 40 kA or more.

(9) Accessories

Refer to Paragraph 6.4.5.

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Chapter 7 Electrical Equipment

6.4.3

High tension power distribution board (Combination switchboard) (1) General 1) The panel shall be MW class or higher in order to improve reliability and stability and to reduce faults. Distribution board shall not be installed at a place where dust can easily be produced. But it can be installed at a plant where especially frequent on/off is not necessary. 2) Dust proof facilities shall be taken into consideration to protect switchboard. 3) In case of using VC, method of reducing surge voltage that occurs at the time of on/off shall be taken into consideration. (2) Type Vertical self-standing metal clad, dust proof type for indoor or outdoor use (IP54) (3) Structure 1) Swing door with locking devices in the front and rear side of the panel, and the panel shall have the structure to draw out combination switch in front side of the panel. Control circuits shall be connected with multiple plugs. 2) The number of piling-up shelves for circuit breaker shall be 2 or less. 3) The space of cable head shall be wide enough to facilitate cable head treatment maintenance and inspection. Metallic wall for cable way shall be installed at cable room under the switch. 4) CV cable shall be used. Bracket for cable head mounting shall be installed. 5) The support of high voltage bus shall be a porcelain insulator or an epoxy resin. 6) Acrylic plate shall be installed in the front of fuse and contactor to protect inspectors from electric shock during inspection. 7) Rubber packing shall be inserted to front door and rear cover for the sake of dust-proof for outdoor use. (4) Bus system 3 phase 3 wire Single bus (5) Rated circuit voltage: 7.2kV, 12kV (6) Insulation level: 6B,12B (7) Composition of Combination Switch 1) Power fuse ① Rated voltage: 7.2kV, 12kV ② Rated current: The supplier shall determine it according to loads’ capacity.

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Chapter 7 Electrical Equipment

③ Fuse blown indicating device shall be installed. The status of

blowing out shall be easily seen. And attaching auxiliary contact to a fuse contact shall be able to be connected with external terminals. ④ T type for transformer and M type for motor shall be used. 2) High voltage vacuum contactor ① Type: Vacuum ② Rated using voltage: 7.2kV ③ Rated breaking capacity: shall be determined by individual specification. ④ Switching capacity: As per IEC Standards ⑤ Switching frequency: As per IEC Standards ⑥ Life: IEC Standards. (8) Accessories Refer to Paragraph 6.4.5.

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Chapter 7 Electrical Equipment

6.4.4

Low tension power distribution board (1) General It shall be applied to low voltage distribution switchboard composed of Air Circuit Breaker (ACB), Molded Case Circuit Breaker (MCCB), etc. which are connected with 600V lines or lower. (2) Type Vertical self-standing, enclosed distribution switchboard for indoor use. (3) Structure 1) ACB panel shall be less than 2 piling-up shelves 2) IEC947-1 shall be applied correspondingly. 3) ACB type with front and rear side door shall be front side draw-out. 4) Circuit breaker, common bus, branch conductors, current transformer for instrument and cable terminals shall be equipped. Metallic partition wall shall be grounded. 5) All the main circuit terminals shall be located at the bottom of the rear side of each board and there shall be enough space to pull distribution cable adequate for the capacity of ACB and MCCB. For the charging part of the rear side bus, protective cover having structure of being able to see the inside shall be installed. (4) Setting circuit breaker 1) Air Circuit Breaker (ACB) ① Type: ACB with over current trip relay ② Rated voltage: 600V ③ Rated current: The supplier shall propose the capacity according to the loads. ④ Operating method: Electromotive operation (Manual operation is also available.) ⑤ Application: Incoming, bus tie (greater than 800A) Outgoing feeder (greater than 1,000A) 6)

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Chapter 7 Electrical Equipment

2) Circuit breaker for distribution ① Type: Circuit breaker with time delay and instantaneous over

current trip ② Rated voltage Nominal voltage of lines

Rated voltage of circuit breaker for distribution

AC 380V

AC 550V

AC 220V

AC 250V

AC 110V

AC 250V

AC 220/110V

AC 250V

(Single phase 3 wire) DC 380V

DC 500V

DC 220V

DC 250V

DC 110V

DC 250V

③ Rated current: The supplier shall propose the capacity according to

loads. (5) Bus type

3 phase 3 wire single bus (6) Accessories

Refer to paragraph 6.4.5.

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Chapter 7 Electrical Equipment

6.4.5

Accessories of power distribution board

Voltage

30kV Circuit breaker board

Kinds

Item

Potential Transformer (PT)

DS board for power receiving

○

Current Transformer (CT) Voltmeter

6kV

Receiving

○ ○

(○)

Feeder

Circuit breaker board DS board for power receiving

○ ○

○

Low voltage

Receiving

○ ○

(○)

Feeder

○

○

Combination Switchboard

Receiving

(○)

○

○

○

(○)

○

Ammeter

(○)

(○)

○

(○)

(○)

○

Ammeter changeover SW

○

○

○

○

(○)

○

Wattmeter

○

○

○

(○)

(○)

Watt-hour meter

○

(○)

○

(○)

(○)

Ground fault detection device

○

○

○

○

○

○

Zero phase voltmeter

○

○

○

Remarks Feeder

○ Changeover switch attached ○

(○) ○ ○

Residue indicator attached DS shall be needed in a place where circuit is operated.

(○)

○

○

(○)

○

○

○

○

○

Control power switch

○

○

○

○

○

○

○

○

(○)

○

○

○

○

○

○

○

Negative-phase protection Pilot lamp for electric source

For remote monitoring

○

Operation switch

Protective relay

Changeover switch attached

○ ○

○

○

○

7-50

(○)

○

White

Chapter 7 Electrical Equipment

Voltage 30kV Kinds DS board for power receiving

Item

Pilot lamp for grounding

6kV

Circuit breaker board Receiving

Feeder

○

DS board for power receiving

Low voltage

Circuit breaker board Receiving

○

○

Feeder

Combination Switchboard

Remarks Receiving

Feeder

○

Transparent

Pilot lamp for operation

○

○

○

○

○

○

○

○

○

Terminal for test

(○)

(○)

(○)

(○)

(○)

(○)

(○)

(○)

(○)

DOOR SWITCH

○

○

○

○

○

○

○

(○)

(○)

○

○

○

○

Current recorder

(○)

(○)

Power recorder

(○)

(○)

VAR-meter

(○)

(○)

(○)

VAR recorder

(○)

(○)

(○)

Others

○

○

○

Note)

○

○

Red

For board lighting

1. ( ) shall be decided by the agreement. 2. This table deals with basics. Detailed specification shall be decided by the agreement. 3. Attaching method of each device shall follow IEC standards.

Note)

1. OCR among protective relays shall be installed to all 3 phases and shall be draw-out type. 2. In case CT ratio exceeds 400/5, ground fault current shall be detected with tertiary winding. The strength of short shall be determined by short circuit capacity of the system.

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Chapter 7 Electrical Equipment

6.4.6

Motor control center (1) General 1) Charging part of the board that can be touched by men shall be protected by partition, tube, tape, etc. 2) Ground fault detection and indicating devices shall be installed in every unit of motor and MCCB circuits. 3) One switching device for one load shall be installed. But it is permitted to install a switching device at each group for the following description. (In this case, protection shall be given separately.) ① Fan for fan coil unit ② Fan for transformer cooling ③ Roller table for group operation ④ Vibrator for group operation 4) In reversible operation facilities reversing magnetic contactor shall be electrically interlocked. Mechanical interlock shall be installed at important facilities indicated. 5) Ammeter shall be installed at important loads feeder and motors feeder above 45kW. If possible, Digital protective relays shall be applied instead of ammeter and EOCR. (2) Control center type 1) Type Indoor simple control center type 2) Structure ① Swing door that possesses locking devices in front side and rear side shall be prepared. Panel shall be composed of units and be separated by partitions. Plug type connection system shall be used to connect to control circuit terminals. -- > It’s fixed or draw out type of MCC. ② In principle, control equipment shall be installed at each motor feeder. ③ Terminals connected to external power shall be installed on the back of each unit. Terminals for load control shall be installed on the bottom of panel and the back of each unit. The space of terminal board shall be wide enough to make it easy to connect cables. ④ The bus shall be electrically and mechanically strong enough to endure 3 phases short status. 3) Circuit voltage: 380V, 50Hz 4) Accessories: Refer to Paragraph 6.4.6 (6).

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Chapter 7 Electrical Equipment

(3) Electronic control board type 1) Type: Enclosed self-standing type 2) Structure ① In principle, front and rear side door type shall be used. ② When turning on or off the circuit breaker for distribution,

charging part shall not be touched structurally. Connection terminals for external shall be installed at the bottom of the panel in groups divided into power, load and control terminals. 3) Rated voltage: More than 380V (Panel of 200Vclass shall be 220V) Circuit operating voltage: AC 220V or AC 110V 4) Accessories Refer to Paragraph 6.4.6 (6). ③

(4) Thyristor converter

The design standard of thyristor converter for motor shall be as follows. 1) General specification ① Usage : Thyristor converter Current control device Voltage control device : Primary and secondary voltage ② Voltage shall follow the maker’s standard. ③ Rating : 100% continuous rating or to be specified by KRI. : The maker’s standard or to be ④ Allowable overload specified by KRI. ⑤ Circuit System : In principle, double way connection or double converter double way connection without circulating current ⑥ Phase No. of rectification : Combined 12-phase or 24-phase or 36-phase for large plant ⑦ Cooling : Forced air cooling Water cooling shall be used only for large current. ⑧ Standard : Refer to IEC-146 . 2) Circuit system

It shall follow the below description. ① In case of large capacity or position control, regenerative braking type shall be used by considering power save and dynamic electric braking and economic efficiency. ② In case of delicate position control, gate pulse control circuit shall be cosine type to make the motor output speed, affected by the variation of input voltage, unchangeable. ③ In case the control object is a normal load that is not affected by the speed change, gate pulse control circuit shall be triangular wave control type. 7-53

Chapter 7 Electrical Equipment

3) Consideration of harmonics

In case the harmonics generated by thyristor converter of mill motor exceeds the restriction, harmonic filter shall be installed. In this case the power factor for design condition shall be 90%. 4) Thyristor set ① Type: It shall be cubicle type. ② Control circuit a. To select -limit, fluctuation of power voltage and over load rate shall be taken into consideration and safety operation shall be continued at low voltage. (80% of rated voltage) b. Variable -limit System or the equivalent c. For circuit breaking, gate suppression shall be needed at first, trip of DC high speed circuit breaker at second step and blowing fuse for element shall be necessary to prevent element from being damaged. Protection characteristics curve shall be submitted d. Fuse for element protection shall not be blown when current becomes off state during decelerating. ③ Maintenance a. It shall be taken into consideration that thyristor element and fuse can be exchanged quickly. Each thyristor cell and fuse shall be able to be replaced individually in more than 1,000A thyristor converter. Tools for that purpose shall be included in purchase items. b. Trouble shooting device shall be prepared to check fault in control circuit. - Instrument to check voltage and current of control circuit. - It shall be easy to observe wave curves. - Indication lamp for relay operation, Indication pilot lamp for power and fault (accident) 6) Cooling ① Adoption items a. Water cooling system : Shall be only applied to large current, low voltage b. Unit cooling system : For large facilities c. Air conditioning system : For medium scale facilities d. Ventilation : For small facilities e. Freon boiling system : For large facilities

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Chapter 7 Electrical Equipment

②

Notices a. Circulated water shall be used as cooling water for cooling system according to ISZ-2 Chapter 1. b. It shall be deeply considered of being frozen to burst in winter. c. Clean make-up air shall be arranged for water cooling unit and air conditioning equipment. d. Noise level in electric room where air-cooling thyristor cubicle is installed, shall be minimized. 7) Transformer and reactor for rectifier ① Transformer and reactor shall be dry type or incombustible oilfilled type. If oil-filled type is installed inevitably, the following steps shall be taken. a. Exhaust groove shall be prepared to drain leakage oil quickly. b. They shall be installed in an insulated and isolated room. c. Fire protection system shall be prepared. ② Transformer for rectifier a. -limit for secondary voltage shall be decided after considering the value of voltage fluctuation range of electric source, voltage drop in line, allowable overload, phase shift tolerance angle and overlapping angle. b. In case primary voltage is 30kV, surge arrestor and insulating plate for contact protection shall be installed to secondary side. ③ Small capacity of reactor (air cooling type) shall be installed in control panel. 8) Accessories Refer to Paragraph 6.4.6 (6). (5) Variable frequency inverter 1) General specification ① Usage : Variable Voltage Variable Frequency Inverter for AC Motor ② Standard : IEC 146, IEC 146-2 ③ Voltage : Primary and secondary voltage shall follow the standard of maker. ④ Rating : Shall be 100% continuous rating or to be specified by KRI. ⑤ Permissible : Maker’s standard or to be specified by KRIIndonesia. ⑥ Circuit system : Static Converter-Inverter System ⑦ Cooling : Forced Cooling Water Cooling System

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Chapter 7 Electrical Equipment

2) Inverter ① Type : Cubicle type(Unit enclosed distributing panel)

Small capacity of inverter shall be installed in control panel. ② Circuit a. Controller shall be static, converter-Inverter and variable frequency type. b. Voltage surge type shall be applied for small capacity and current source type shall be applied for large capacity. c. Controller shall include all the logics that are needed to operate speed controller on plug-in printed board. d. Electric isolation between power and control circuits shall be taken into consideration. ③ Maintenance a. It shall be taken into consideration that power modules (Thyristor, Transistor, and IGBT) and fuse can be exchanged quickly. Tools for that purpose shall be included in purchase items. b. Trouble shooting device shall be prepared to check fault in control circuit. - Instrument to check voltage and current of control circuit. - It shall be easy to observe wave curves. - Indication lamp for relay operation, Indication pilot lamp for power and fault(accident) 3) Transformer and reactor for inverter ① Transformer and reactor shall be dry type or incombustible oilfilled type. If oil-filled type is installed inevitably, the following steps shall be taken. a. Exhaust groove shall be prepared to drain leakage oil quickly. b. They shall be installed in an insulated and isolated room. c. Fire protection system shall be prepared. ② Transformer for rectifier

a. -limit for secondary voltage shall be decided after considering the value of voltage fluctuation range of electric source, voltage drop in line, allowable overload, phase shift tolerance angle and overlapping angle.

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Chapter 7 Electrical Equipment

b. In case primary voltage is 30kV, surge arrestor and insulating plate for contact protection shall be installed to secondary side. ③

If necessary, output transformer shall be prepared for nigh voltage AC motor. ④ Small capacity of reactor (air cooling type) shall be installed in control panel. 4) Accessories Refer to Paragraph 6.4.6 (6).

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Chapter 7 Electrical Equipment

(6) Accessories for electric control board

Classification

Kind of units

Accessories - Main circuit breaker :

For main circuit breaker

For control transformer

-

Control center type

For direct on-line motor

-

For primary starter motor

-

3 poles ACB(1,000A and above) 3 poles circuit breaker for distribution line (less than 1,000A)

Potential transformer Voltmeter Pilot lamp: indicating power On/Off Others 2 poles or 3 poles circuit breaker for distribution: For transformer protection 2 poles circuit breaker for distribution: For control circuit Pilot Lamp: Indicating power On/Off (white) Transformer: For power control 3 poles breaker for distribution: For Line Magnetic contactor (Including protective relay): A class ※For reversible motor : 2 sets of magnetic contactor and 2 CTs Control Switch (Cam Switch or Push Button Switch) ※CS or PB shall be installed individually, if control power and machinery are located in different place. Pilot Lamp: For operation indication (R:stop, G: run, Y: fault) Reset device for protective relay AC ammeter: More than 45kW or where required Others 3 poles magnetic contactor: For short of starting device Starting device One among the below systems shall be adopted. a) Y-△ starting: For general use b) Reactor starting: For general use c) Resistance starting: For general use It shall be applied only when starting frequency is low. Auxiliary relay and timer AC ammeter Current transformer

7-58

Chapter 7 Electrical Equipment

Classification

Kind of units

For low voltage, Control 3 phase winding center type type Induction motor

Electronic control board type

Accessories -

Magnetic contactor for starting Relay for accelerating Other necessary components Secondary resistor Steel grid resistor for electric resistor (temperature rise shall be lower than 350℃)

-

3 poles circuit breaker for distribution:

-

For main distribution For motor circuit 2 poles circuit breaker for distribution: For operation circuit Magnetic contactor Auxiliary relay Protective relay Ammeter (larger than 45kW or where required ) Current transformer (if necessary) Operation indication lamp (R: stop, G: run, Y: fault) Others necessary [Accelerating relay] [Accelerating magnetic contactor] Note. [ ] is applied to winding type motor

Thyristor Converter

-

Detailed specification shall be decided by agreement.

Variable frequency inverter

-

Detailed specification shall be decided by agreement.

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Chapter 7 Electrical Equipment

6.4.7

Control system (1) General 1) Control power ① In principle, it shall follow Paragraph 6.4.1 (3). ② Control power shall be divided by MCCB and insulating transformer into facility unit and usage (For electronic valve, relay panel, etc.) 2) Name plates (device coherent to sequence) which represent the usage shall be attached to the top or bottom, where easily to be seen, of the relays, MCCBs, fuses, etc. in the control board. 3) Terminal of MCCB and bus in distribution panel board, etc. which men may touch shall be insulated to prevent electric shock. 4) Main circuit shall be open when contactor is turned off. And, open confirming indication lamp which is turned on by the auxiliary contact of main circuit, shall be installed. (2) Relay panel 1) Type: Enclosed self-standing type 2) Structure: The front shall be door type. The back shall be door type or bolt tightened type. But, in case of double-faced type, front and back door type shall be used. 3) Notices ① Relay being used shall be easily determined its status of operation by way of lamps or others.. ② Electromagnetic valve power and general control power shall be distinguished. ③ Wiring in boards shall not cause abnormal operation because of inductive disturbance or others. (3) Programmable Logic Controller 1) General ① The kind of PLC shall be decided by consultation with KRI in advance. ② Extension space shall be enough to install input-output equipment and peripheral equipment additionally. ③ The communication method shall follow international standards like ISO, CCITT, IEC, IEEE. ④ In case, when assembling devices, the conditions required to each devices of temperature, humidity, dust-proof and earthquake-proof, etc. are different from KRI’s specified conditions, the supplier shall consider a counter plan and carry it out. ⑤ When interfering with operation by instantaneous voltage drop, Uninterruptible Power Supply shall be installed.

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Chapter 7 Electrical Equipment

⑥

All the elements composing boards such as main memory, CPU, I/O, etc. shall be structured in plug-in type to make it easy to replace ⑦ The method to prevent noise shall be fully established considering installation circumstances. ⑧ Control powers for CPU or I/O shall be distinguished. 2) Hardware ① I/O part shall follow the below a. Input-output devices shall be insulated. b. Operation indication lamp shall be installed in all the contact of input-output. c. Surge absorber shall be installed at contact output part. d. Filter shall be installed at input signal of DC input module. ② Peripherals a. Loader b. Necessary accessories such as hard copiers, printer, software storage device, etc. ③ Spare part a. It shall follow Paragraph 1.2.5. 3) Software ① Programming and debugging software shall be entirely made in the plant of the supplier and at the site, only the modification of the adjusting result in operation test shall be done. ② System design specification which precisely describes the considering items of design such as program, flow chart, subroutine, etc. shall be submitted; and after the completion of adjusting test, it shall be re-submitted with a complete modification of the revisions. ③ Performance capacity and execution managing time after completion of adjusting test shall be submitted. ④ In case the power is off, I/O shall be Fail Safe. ⑤ I/O list, program list and interface signal list as documents shall be submitted after test arrangement has been finished. 4) Self diagnostic function ① Self-diagnostic function on the program setting such as power, CPU, main memory, Bus, I/O, etc. shall be available. ② The following shall be checked always, and be able to be indicated in case of troubles. a. Supervision of power state b. Supervision of CPU c. Supervision of memory parity d. Supervision of communication state

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③

In data transmission system, the followings shall be checked always and in case of troubles, the function of safety counter plan such as rebooting, disconnecting units in trouble, etc. shall be included. a. Supervision of power state b. Parity Error c. Cable disconnection d. Transmission format check e. Supervision of performance time (4) Supervisory panel 1) Dimension, form and location ① Supporting rod shall be mounted in case of upward open top. ② The bottom of the panel shall be covered with steel plate or Bakelite plate with holes for wiring to protect from flame and rats. ③ In case vertical self-stationary type supervisory panel is installed behind desk, it shall be 1~1.2m apart from the wall. In this case the desk type shall be adopted and its height shall be 1,200mm or below. ④ Supervisory panel shall be of graphic or heliographic type. Judgment through watching operation flow and operation state of facilities shall be possible. 2) Items to be mounted 1) Size, color and management of accessories shall conform to International Standards. But complicated equipment like rolling mill table shall be selected by close consultation with KRI. 2) For protection and maintenance of control circuit, circuit breakers for wiring shall be installed at proper location on control circuit. 3) General indicator ① General indicator shall be as follows: Classification Indicating heavy faults (Bell alarming) Indicating light faults (Buzzer alarming) Indicating normal operation ②

Color

Remarks

Orange Flicker

In case indicators are added to the existing panel, it shall be used with the same method as existing one.

Orange Point Milk White Point

The distance between numbers shall be 7mm or more. The numbers shall be able to be read and understood from a

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distance. ③ Indicators shall be arranged by groups to make it easy to operate, investigate, communicate and respond. ④ Instruments and devices which are not controlled and supervised shall be installed under the self-stationary panel. 4) Pilot lamp color The color of pilot lamp lens shall be as follows. Classification

Color of lens

Remarks

Switching on of D.S breaker switching device

Red

At automatic breaking, Flicker

Switching off of D.S breaker switching device

Green

Pilot lamp for indicating trouble

Orange

Pilot lamp for indicating power source

Milk White

Pilot lamp for indicating ground fault

Transparency without any color

Normal operation indication

Milk White

(5) Operating desks

1) This part is applied for desk type operating desks built in operator room. 2) Switches for starting are arranged to the left side , those for driving are to the middle part and those for stop are to the right side on the desk. 3) Emergency switches should be 1.5~2 times bigger than others and have cover to avoid mis-handling. 4) The height of desk panel is decided on the condition of eyes’ height 1,135mm of operator when there are something to observe behind the desk. 5) The following figure is recommended dimensions for operating desk .

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Chapter 7 Electrical Equipment

Control Panel

(d)

Keyboard 부

(e)

Rounding

(f)

(g)

(a)

(b)

(C)

(c ) Description

Size (mm)

a

Desk body ~ End

390~

b

Height of controller

670 (590~730)

c

Space for leg

250

d

Length of control part

500

e

Angle of VDT

75° (70~82)

f

Angle of Control Button part

15° (10~20)

g

Height of Console

1150

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Chapter 7 Electrical Equipment

6.5

Rotary machines 6.5.1

General (1) Related standard KS –C –4001 : General rules for rotating electric machine KS –C –4202 : Low voltage 3 phase induction motor (for general use) KS –C –4203 : High voltage (6kV) 3 phase induction motor(for general use) JEC – 37 : Induction motor JEC – 54 : DC motor JEC – 114 : Synchronous motor JEC – 146 : The general of rotating electric machine JEM – 1041 : Primary starter for AC electric motor JEM – 1109 : For rolling mill auxiliaries and AC motor for crane JEM – 1120 : DC electronic brake for rolling mill auxiliaries and AC motor JEM – 1157 : DC electric motor for rolling mill JEM – 1170 : DC electric motor for industry JEM – 1188 : Rated output standard of motor JEM – 1201 : Explosion proof low voltage 3 phase squirrel cage type induction motor JEM – 1202 : Totally enclosed winding type low voltage 3 phase induction motor for crane JEM – 1224 : Load allowable value of high voltage 3 phase squirrel cage type induction motor JEM – 1240 : AC operated brake of totally enclosed winding type low voltage 3 phase induction motor for crane JEM – 1380 : Size of high voltage (6kV) 3 phase squirrel cage type induction motor (General F class) JEM – 1381 : Characteristics and noise of high voltage (6kV) 3 phase squirrel cage type induction motor (General F class) JEM – 1313 : Noise level of general 3 phase squirrel cage type induction motor JEM – 1400 : Size of general low voltage 3 phase squirrel cage type induction motor JEM – 1401 : Size of general flange type low voltage 3 phase squirrel cage type induction motor. And the other related standards IEC 60034-1/2

Rotating Electrical Machines

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Chapter 7 Electrical Equipment

(2) Rated output of electric motor

Rated output is indicated as kW. Rated output standard over 0.2kW and less than 1,000kW shall follow the below table. Items that are not discussed in this table shall be confirmed by KRI. Caged type Low voltage

0.2kW 0.4 0.75 1.5 2.2 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 132 150 160 200

High voltage ( 55)kW ( 75 ) ( 90) (110) (132) (150) (160) (200) 250 280 315 355 400 450 500 550 630 750 800 900 1000

Woundrotor tupe

DC MOTOR for rolling mill auxiliaries and crane motor

3.7kW 5.5 7.5 11 15 22 37 52 75 110 150 185 205 280 370

2.2kW 3.7 5.5 7.5 11 15 22 30 37 45 55 75 90 110 132 160 200

Note) The numbers of ( ) shall be applied according to distribution line.

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DC electric motor for industry

0.37kW 0.55 0.75 1.1 1.5 2.2 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 132 160 200 250 315 400

Chapter 7 Electrical Equipment

(3) Voltage division of AC motor

It is basically determined as follows. 1) AC 380V class The rated output is not more than 150kW 2) AC 6,000V class The rated output is over 150kW. 3) AC 11,000V class It is indicated in each specification. (4) Application division of starting device of AC motor 1) 380V 3 phase squirrel cage type induction motor 110kW or the above shall be determined after discussion. 2) 6,000V 3 phase squirrel cage type induction motor ① Direct On Line (DOL) starting method shall be applied to less than 500kW. But motor of which starting exceeds 3 times a day shall be determined after discussion. ② Over 500 kW motor shall be determined through mutual agreement. (5) Note on rotary machine 1) Vibration monitoring equipment of the motors shall be installed according to the below, and vibration shall be measured at both shafts of the motor in H-direction ① Motor that is more than 350kW and 750rpm at blower ② Motor that is more than 500kW and 750rpm except blower ③ Motor that is more than 150KW and 3,000rpm However, the vibration monitoring equipment installed in a main body of the machine may not be installed in the motor. 2) Motor on which decelerator is attached shall have the power of 37KW or below. When it is frequently started or reverse operated, it shall have enough strength. (need to be clarified later) 3) When fixing cover of main motor or inspection tools it shall be taken into consideration that bolt and nut of motor shall not be dropped. 4) Lubricating grease shall be fed safely even in operation. But served type shall not be like that. (6) Protecting and cooling method 1) DC motor and generator for rolling mill. : Open enforced air-cooling, drip proof and air-circulated type shall be used. 2) DC motor for rolling mill auxiliaries (including crane) : Totally closed internal cooling type with drip proof structure (one hour rating); Opened and enforced air cooling (continuous rating) 3) DC motor for industry :Opened drip proof, totally enclosed and opened and enforced air cooling type

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Chapter 7 Electrical Equipment

DC generator for rolling mill auxiliaries: Opened and drip proof type or one that has better quality than that 5) AC motor Low voltage High voltage Indoors Outdoors Indoors Outdoors Less dust Much dust - Under - Under 300kW - Under 1000kW 1000kW : Totally : Totally : Opened drip enclosed type enclosed Totally proof - 301~1000kW type for Totally enclosed protection : Totally outdoor use enclosed fan type enclosed type or Over 1000kW fan cooling Over opened and : Totally cooling type for 1000kW enforced drip enclosed type outdoor : Totally closed proof type internal use internal (Fan that is cooling type cooling type Installed in for outdoor Frame) use Totally Totally enclosed enclosed fan fan cooling cooling type for type outdoor use - Under 1000kW - Under 300kW - Under 1000kW : Opened and : Totally : Totally drip protection enclosed enclosed Totally type type type for enclosed Totally - Over 1000kW - 301~1000kW outdoor use type enclosed : Totally : Totally - Over 1000kW Opened type for enclosed enclosed type : Totally and drip outdoor internal or opened and enclosed protection use cooling type enforced drip internal cooling type protection type type for (Fan that is outdoor use installed in Frame) 4)

Kinds

General 3 phase squirrel cage type induction motor

3 phase wound type low voltage induction motor for crane

3 phase wound type induction motor and 3 phase high voltage synchronous motor

Note) If necessary, anti-corrosion or explosion proof type shall be applied.

(7) Cooling water 1) Lubricating oil cooler : Clean water 2) Air cooler : Recycled water in principle. 3) Power plant : Sea water

The quality of cooling water shall follow Chapter 1 SZ-2. (8) Air cooler 1) Anti-corrosion type shall be applied. 2) It shall be easily cleaned and structured simply. 3) Leakage inspection device shall be installed.

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(9) Bearing 1) Dial type thermometer shall be installed in the rotary machine of

500KW or higher to measure temperature of bearings. 2) Lubricating grease for bearing shall be selected according to the characteristics of bearing except the sealed type rolling bearing. (10) Starting number of the motor AC motor shall endure 3 times of continuous starts (1 hot, 2 cold) while connected to a load. Continuous starting procedure: Motor shall be started under normal temperature condition. Just after revolution of motor reaches its full speed, turn off the motor switch. When rotating speed becomes 5% of rated speed, it will be restarted. Continuous starting test shall be done three times. (11) Frequency of AC machinery: 50Hz (12) Others 1) If there is no special requirement, space heater shall be installed for more than 150kW(280Fr) rotary machine. 2) Thermometer for cooling air (ventilation) and air flow detection sensor shall be prepared at more than 1000kW rotary machines.

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Chapter 7 Electrical Equipment

6.5.2

DC motors for rolling mill (1) Protection and cooling method: It shall follow 6.5.1 (8) (2) Voltage: It shall be selected among DC 1200V, 750V, 600V, 380V (3) Rating: Continuous rating (4) Over load capacity: It shall follow the standards of IEC, JEM, NEMA, BS, (5) (6) (7) (8)

and DIN. Insulation: F, H class Temperature rising: It shall follow the standards of IEC, JEM, NEMA, BS, and DIN. Brush: It shall follow the standard of the maker. Brush holder shall be constant pressure type. Special matters 1) Insulation design: Any charged part shall not be exposed externally except rectifier and brush. Coil’s ending parts and near distance from back of rectifier shall be taken into consideration by insulation design. 2) Rectifying characteristics: Harmful spark shall not be produced even

by an electric fault while decelerating from fastest speed.(especially for the power source of thyristor) 3) Thermometer: More than 3 temperature detection devices shall be installed at compensation winding and others of major motors. 4) Yoke: It shall be lamination structure. 5) Shaft current prevention device shall be installed and it shall be highly reliable to be able to use for years. (9) Generators shall follow the specification of motors.

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Chapter 7 Electrical Equipment

6.5.3

DC motors for rolling mill auxiliary machine (including crane) (1) Protection and cooling method: It shall follow 6.5.1 (8) (2) Voltage: DC 220V In case of double voltage control, it shall be 220/380V. (3) Field voltage: In case of separate excitation, it shall be DC 22V (4) Rating: Continuous rating or short time rating Rating shall follow the standard of JEM 1109 or the equivalent. (5) Control method and control scope 1) Rotating direction: Reversible or non-reversible 2) Control method: Positive voltage control, variable voltage control or field control. 3) Control scope: It shall satisfy the following. ① Any frame numbers shall be controlled to be maximum 550V of variable voltage. ② Field control scope shall be as follows. Frame Number 802 803 ~ 804 806 ~ 810 812 ~ 818, 620 622, 624

Speed limit 200% 250% 300% 250% -

(6) Insulation class: B, F, H class (7) Temperature rising: Under commutating power source, it shall follow

the standard of JEM 1109 or something like that. (8) Voltage capacity: It shall follow the standard of JEM 1109 or something like that. (9) Maximum starting torque and operating torque: It shall follow the standard of JEM 1109 or something like that. (10) Structure 1) 2 separation or non-separation structure yoke. 2) Cooling air direction: Basically, it shall be supplied from commutator 3) Insulation reinforcement Insulation in coil’s ending parts, riser and the backside of commutator shall be strengthened and salt proof and moisture proof also shall be strengthened by epoxy resin mold. 4) Blind cover shall be installed in flange hole of ventilative parts. 5) Protection device shall be installed in ending part of shaft to prevent deformation or damage while in transportation. 6) Accessories of brush

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Chapter 7 Electrical Equipment

① Insulation of locker arm: same with item 3). ② Brush holder shall be constant pressure type.

Even when removing scale by water or spaying, waterproof shall be considered. (11) Low inertia DC motor 1) Application: It shall be used at low GD²of screw down motor , etc.. 2) Insulation class: B, F, H class 3) Structure: Separation or non separation structure yoke 4) Others: Voltage, rated rotation number, maximum torque and size shall follow what is defined above. (12) Generators shall follow the specification of motors. 7)

6.5.4 Industrial DC motors (1) Protection and cooling method: It shall follow Paragraph 6.5.1 (8) (2) Voltage : DC 220V or DC 380V (3) Rating : Continuous (4) Field winding: shunt, stable shut and complex (5) Over load capacity: 150% (6) Insulation class: B, F, H class (7) Temperature rising: It shall follow the standard of JEM 1170 or

something like that. (8) Measures for salt contamination: Insulation treatment shall be made more strongly at coil ending parts, riser and backside of commutator for prevent moisture proof and salt proof.

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Chapter 7 Electrical Equipment

6.5.5

3 Phase induction motor (1) Squirrel Cage type

Classification 1. Protection and cooling method

2. Size

3. Kinds

Low voltage

High voltage

Paragraph 6.5.1 (8)

Same with the left

IEC, ISO,KS, JEM, NEMA, BS, DIN or the equivalent

Maker’s standard

General squirrel cage type (shall satisfy the starting torque according to the characteristics)

Special squirrel cage type

4. Rotation number IEC, ISO, KS,JEM, NEMA, BS, DIN or the equivalent

Same with the left

5. Voltage

380V(220V)

6600V

6. Rating

Continuous rating

Same with the left

7. Insulation

E, B, F class

B class, F class, H class

8. Bearing

Anti-friction

Maker shall select it and be confirmed by KRIIndonesia.

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Chapter 7 Electrical Equipment

(2) Wound type

Classification

Low voltage

High voltage

1. Protection and cooling method

Paragraph 6.5.1 (8)

Same with the left.

2. Dimension

Maker’s standard

Maker’s standard

3. Output

Maker’s standard

Maker’s standard

4. Rotation number

Maker’s standard

Maker’s standard

5. Primary voltage

415 V

Over 6.6 kV

6. Secondary voltage

Maker’s standard

Maker’s standard

7. Rating

% ED: 15%, 25%, 40%, 60%, 100% shall be standard

Same with the left.

8. Insulation

E, B, F class shall be selected to be coincident with %ED.

Same with the left.

9. Back torque

Shall be over 160% of 40%ED rated torque at same frame number. * Reference Crane: Over 250%

Over 175%

10. Bearing

Anti-friction

11. Shaft

Both shafts

12. Standard

IEC, ISO, KS,JEM, NEMA, BS, DIN or the equivalent

Maker’s standard Maker’s standard

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Same with the left.

Chapter 7 Electrical Equipment

6.5.6

High voltage 3-phase synchronous motors (1) Type: It shall follow 6.5.1(8) (2) Dimension, output and speed: shall follow the standard of maker (3) Voltage: 6600V, 11000V (4) Field 1) Field voltage: Decided by maker 2) Field power source: Basically semiconductor rectifier (5) Power factor: Decided by KRI (6) Rating: Continuous rating (7) Insulation: Above B class

Field circuit shall be considered sufficiently for salt proof and moisture proof. (8) Brush: Basically there shall be no brush. (9) Field adjustment method: Constant exciting, AVR and AQR shall be determined by KRI.

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Chapter 7 Electrical Equipment

6.6 Electrical equipment for machinery 6.6.1

Fan and blower Electric design of ventilation fan of sintering plant and raw air compressor of oxygen facilities shall be based upon this standard. But, for small facilities, the function or specification of this standard can be weakened. (1) Motor for main facilities 1) Specification ① Basically it shall be 3 phase squirrel cage type induction motor 2. ② Generally squirrel cage type is not adequate to big GD Motor shall be selected according to the following conditions. (a) When total voltage starting time is within 15 seconds: squirrel cage type (b) When total voltage starting time is within 15~30 seconds: special squirrel cage type or wound type (c) When total voltage starting time is more than 30 seconds: Wound type ③ When speed control is needed, wound type or variable speed motor shall be used. ④

Synchronous motor more than 2000kW class may be selected. 2) Type: It shall follow Paragraph 6.5.5 and 6.5.6. 3) Starting method ① Squirrel cage type (a) Basically low voltage starting (b) Prevention equipment for starting failure shall be prepared for reduced voltage starting method. ② Wound type (a) Starting operation shall be automatically proceeded for accelerating of secondary resistor and secondary circuit’s short. (b) If prevention equipment for starting failure is operating, adequate management shall be done.

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Chapter 7 Electrical Equipment

6.6.2

Pump (1) Motor for main pump 1) Type: Basically special squirrel cage type induction motor 2) Basically dial type thermometer that has alarming contact point shall be installed at motor bearing more than 200KW. 85℃ - Serious fault 75℃ - Warning fault 3) Terminal and terminal box Terminal box of outdoor motor shall be water proof, dust proof and salt proof. Connection terminal of outdoor cable shall be installed inside the terminal box and be fixed at insulation plate of moisture proof and fire proof. (2) Electric equipment of motor-driven water valve 1) Motor for water valve shall be general low voltage 3 phase squirrel cage type induction on which totally enclosed flange type internal brake is equipped. 2) Location indication limit switch (Switching IC connection) and torque limit switch shall be attached to electric equipment. 3) Opened angle transfer device (if necessary) Type: Synchronous transfer device Frequency: 50Hz Voltage: 220V 4) Opened angle receiver (if necessary) Type: Synchronous receiver Form: Wide-angle type, 110mm square, half-stopped type (Attached to control panel) closed 0% - opened 100% (3) Electric equipment for lubricating devices of the water bearing 1) Vertically stand-alone pump shall be equipped with water flow detector that has time relay and magnetic valve. 2) If water failure happens by stoppage of strainer, it shall be alarmed to inspection room. (4) Electric equipment for vacuum pump 1) If positive inhalation head does not exist, vacuum pump starting device shall be used. 2) Motor for vacuum pump shall be low voltage 3 phase squirrel cage type induction motor of general use. (5) Drain pump facilities 1) Pump type: On the water pump (basically) 2) Electric motor voltage : AC 380V, 3φ, 50Hz, or AC 220V, 3φ, 50Hz or AC 110/220V, 1φ, 50Hz

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Chapter 7 Electrical Equipment

3) Control panel ① Control panel shall be wall-attached type. ② Special earth leakage circuit breaker shall be installed to

prevent electric shock. ③ Level switch shall be used to adjust level. ④ Automatic or manual change-over-switch shall be equipped. 4) Rubber hose for drain shall be longer than 10m. 5) 380220V, 3 phase power source for maintenance can be used for drain pump.

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Chapter 7 Electrical Equipment

6.6.3 Emergency generating equipment for driven diesel engine Emergency generating facilities shall basically follow the below specification to supply stable power, in case normal power cannot be supplied. (1) Precondition 1) Duration of Power failure: maximum 2 hours 2) It shall be restarted within 20 seconds after power failure (Power failure confirmation: 1~5 seconds, time to normal operation after confirmation of power failure: 12~15 seconds) 3) Surrounding temperature: -15℃ ~ +40℃ 4) Maintenance: Once a week, operation with no load for 5 minutes (2) Diesel Engine 1) Engine ① Stroke: 3/4 stroke engine ② Combustion way: Direct injection method ③ Cooling method: fresh water cooling, second cooling by sea water system ④ Cylinder structure: V type, series type ⑤ Starting method: by compressed air or battery 2) Accessories ① Oil storage tank Fuel storage tank shall be located out of generating room. The capacity of tank shall be large enough to operate diesel generator for more than 5 hours. Adding fuel to service tank shall be done automatically. (Details are indicated by KRI.) ② Fuel service tank Fuel service tank shall be installed on generator stand or shelf on building’s wall. Flow meter shall be attached to fuel service tank. It shall be able to operate for 6~8 hours at rated load.(consumption rate: about 170~200 gr/ps-H) Note: Fuel tank shall be manufactured, installed and managed according to SNI or International Regulation/Standards.

③ Cooling equipment

Air cooling type or water cooling system shall be used. If water-cooling type is used, secondary cooling water (seawater) system shall be used. Primary cooling water (fresh water or recycled water) system shall be circulated to exchange heat of diesel engine. Make up water shall be supplied to compensate evaporating and leakage. Secondary cooling water (seawater) shall be drained after exchanging heat with primary cooling water (fresh water) at heat exchanger.

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Chapter 7 Electrical Equipment

냉각수용 장cooling Tank Expansion tank확 for water Primary cooling water

1차냉각수

Secondary cooling water (sea water)

2차냉각수(해수)

28-30°C (in 28-30℃(하절 기)

Diesel Engine 열교환기

summer) 설비or 의circulating 해수 또는 Sea water

순환수

water in facilities

Heat exchanger

Primary cooling water pump (connected

1차냉각수 Pump

directly with the engine) (Engine과 직결)

Fig 1. Cooling water system of engine

The best adequate and available method for cooling water system of diesel engine shall be selected. In this case, powers of other facilities are supposed to be stopped. ④ Ventilation equipment (a) Noise: Shall be less than 50~55Phone at 300m apart from engine (b) Muffler and ventilation pipe Noise reduction of muffler: 10~15 Phone Muffler and ventilation pipe shall be thermally insulated. (c) If necessary, supercharge and air cooler shall be installed. 3) Notes ① Protection of diesel engine (a) More than 500kW capacity Engine protection equipment shall be installed according to technology standard related to power electric generation under the following operation condition. ○ Overspeed of diesel engine (Operation less than 116% of rated speed) ○ Cooling water. Temperature’s rising ○ Abnormal low voltage of lubricating oil ② Ventilation

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Chapter 7 Electrical Equipment

When operating diesel engine and generator, the surrounding condition of generating room of diesel engine shall be as follows. (a) Surrounding temperature rising : Less than 40℃ (b) Ventilator with filter shall be installed in engine room. ③ Starting at winter when temperature goes down (indoors –10℃, outdoors -15℃) (a) The temperature of engine room shall be maintained 10~15℃ using steam heater, if possible. (When there is a steam source) (b) Plans for starting engines at winter: Cooling water of engine, heavy oil in fuel supply tank and lubricating oil shall be heated up electrically.(380V power source) ④ Inserting lubricating oil When engine is stopped, all parts of engine shall be lubricated oil for 4 times and 10 minutes each a day using automatic insertion pump. ⑤ Compressed air tank or battery capacity shall be enough to support 3 times of automatic starting. ⑥ Hoist equipment shall be installed at engine room for maintenance. (3) AC generator 1) Type: Basically it shall be self excited open drip proof type. 2) As it is located in same base where engine is also located, if necessary, oscillation prevention equipment shall be installed. 3) Cooling method: Air circulating self cooling type 4) Rotator type: Rotating field pole or cylinder type 5) Connection with engine: Direct connection type 6) Rating ① Capacity, frequency Indicated as KVA and Frequency: 50Hz, Power factor: 0.8(lagging factor) ② Connection Connection of generator: Y connection without grounding 7) Insulation More than B class when it is applied to 6,000 V stator and rotator. 8) Bearing and bearing supporting method ① More than 1,000 KVA and 1,000rpm : Forced lubricating method ② Bearing : Pedestal or Bracket type. But for small diesel generator half side bearing can also be used. 9) Exciting Thyristor or brushless method with automatic voltage adjustment equipment 10) Damper winding

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Chapter 7 Electrical Equipment

Damper winding shall be used to prevent speed change by pulse type torque or hunting of diesel engine when operated in parallel. Pole head is wound by conductors and they are connected with short ring. 11) Space heater of sufficient capacity for generator winding shall be installed to dry moisture when generator is not operated. Basically heater shall be 220V enclosed type. If thermostat is installed, winding and steel core shall not be overheated even though thermostat is out of order and the power is continuously supplied. Maintenance shall be easily done to prevent overheat. High temperature part of heater winding shall be wound with heatresistant wire. 12) Grounding protection of generators shall be done at an adequate part of its main body.

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Chapter 7 Electrical Equipment

(4) The capacity of emergency diesel generating facilities shall be selected

to be maximum value of the following considering that engine and generator can be affected by starting sequence and its method of motor. 1) Capacity needed for normal operation Integrated output of load (kW) Generator rating KVA = Integrated power factor of load x efficiency 2) Capacity according to allowable voltage change value of load and instantaneous voltage drop Xd'(1-ΔV) Generator rating KVA = x 3 x V x Ist x C ΔV Xd'(1-ΔV) = x Pm x B x C ΔV d' : Transient reactance (0.1~0.35) : Instantaneous voltage drop rate (0.25~0.3) ΔV V : Rated voltage Ist : Starting current Pm : Maximum output of motor B : Starting KVA per 1kW with Pm (5.4~9.0) C : Coefficient according to the starting method of motor Direct On Line starting : 1 Y –Δ : 0.67 REACTOR starting : 0.6(60% in case of TAP) Compensator starting : 0.42(5% in case of TAP) 3) Capacity according to generator endurance with maximum load starting Xd'(1-ΔV) Pl - Pm Generator rating KVA = x +(Pm x B x C ) ΔV cosθx η The greatest value of the results from the above equations 1) and 2) and 3) shall be applied as standard output(KVA) of generator. ( This calculation shall be clarified later.)

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Chapter 7 Electrical Equipment

6.6.4

Brake (1) DC Electromagnetic Brake 1) Use ① DC motor for rolling mill auxiliary facilities and crane ② Low voltage 3 phase induction motor, totally enclosed wound induction motor for crane ③ The other general DC motor ④ AC 3 phase motor required for high frequency braking and highly reliability 2) Rating : Short time rating and continuous rating 3) Voltage : DC 220 V 4) Excitement : Parallel or serial 5) Material : Wheel - FC-25 (Gray Cast Iron) at general environment. FCD-50 (Graphite Cast Iron) at environment of high temperature

Shoe - Resin type 6) Brake Torque : Shall follow ISO, SNI, KS, JEM, NEMA, BS, VDE,

IEC or something like that. (2) AC electromagnetic brake AC electromagnetic brake is used at AC motor that doesn’t require frequent brake, because it doesn’t secure a long life compared with DC electromagnetic brake. 1) Type : Enclosed or drip proof type 2) Rating : Continuous or short time rating 3) Voltage : 380V or 220V 4) Insulation : More than E class 5) Frame : Frame number of brake shall be selected after calculating brake torque based on output of electric motor, time rating(or output), voltage, use, on/off frequency and GD². 6) Shoe : Resin 7) Selecting brake ① Disc Brake : AC motor within 15kW; Selection of electromagnetic brake shall be limited according to the installation importance. Example : For prevention of imperfect stop – lathe, milling machine, etc. For sudden stop and slight moving – opening or closing of valve and damper For sudden stop and locking – Hoist, Winch, Conveyor ② Single phase AC electromagnetic brake : AC motor within 5.5 kW Example : For imperfect stop prevention For stop locking For slight moving

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Chapter 7 Electrical Equipment

③

3 phase AC electromagnetic brake : AC motor that requires higher frequency brake and reliability than what mentioned at (1),(2). As KRI select DC electromagnetic brake for crane, AC electromagnetic brake shall be used at 3 phase AC motor except crane. Example : For imperfect stop prevention For stop locking For frequent slight moving (3) Thrust Brake 1) Type : Basic type, Explosion proof type 2) Rating : Continuous or short time 3) Voltage : 220V or 380V 4) Insulation : B, F, H and C class 5) Shoe : Resin 6) Applied regulation : Because it takes longer time to stop by thrust brake than by electromagnetic brake and it takes 0.1~0.5 seconds for operation time, it shall not be used for sudden stopping or precision stopping but used for relatively slow stopping. 6.6.5

Lifting magnet (1) Lifting magnet 1) Type : For specially ordered type like enclosed self cooling type and water using for outdoor use, KRI shall provide the type. 2) Structure : Shall be assembled as one body by welding, having a coil protection plate of ante-abrasion, and shall be reduced the shock to the coil. Insulation protection and strength of lead wire shall be strong enough to endure electrical and mechanical shock and maintain long life. 3) Appearance, size and weight : There is round type, angle type or special type. The size and weight shall be maker’s standard, but the type shall be indicated by KRI. 4) Insulation : B class, H class or C class (or shall be indicated by KRI.) 5) Voltage : DC 220 V 6) Rating : 50% of load time rating (standard) 7) Power consumption: Heated - kW Cooled - kW 8) Kinds : For high temperature or normal temperature

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Chapter 7 Electrical Equipment

(2) Accessories 1) Control unit : Enclosed self stationary dust proof type made of steel

plate 2) Control system – Lifting/dropping out system or number control system of lifting plate. 3) DC power source device : Enclosed self stationary type made of steel plate Main power source: AC 3 phase 380V, 50Hz Rectifier device- Silicon Diode or Thyristor System 4) UPS : UPS shall be supplied to prevent the drop of the lifted object. Hoist time - Select amount 5,10 and 15 minutes

Alkali battery - Floating charging type System - Enclosed self stationary type Capacity: Lifting magnet capacity within hoist securing time

5) 6) 7) 8)

Capacity of electromagnetic brake for hoist Capacity needed for operation of alarm signal The lifted object shall not be dropped by the shock of inching (slightly moving) Cabtyre Cable: BN Cabtyre Cable, 3 class indoor use Self-winding device : Spring type, Torque motor type (AC 3 phase, 380V, 50Hz) Cable Connector : For outdoors The others : Junction box and selection switch box (if necessary) Cable protection spring (Preventing mechanical damage at cable inout hole)

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Chapter 7 Electrical Equipment

7

Construction design criteria 7.1 Lighting 7.1.1

Illumination power source General illumination : Basically AC 3 phase 3 4wires, 380/220V Field illumination : Basically AC 3 phase 3 4wires, 220V or single phase 2 3wires 220V Sub center lamp : AC 3 phase 3 4wires, 380/220V Panel lighting : AC 220V considering the standard of the maker

7.1.2 Standard of lighting fixture (1) General lighting of ceiling 1) Plant building : High pressure sodium lamps or metal halide lamp with high power factor type ballast. 2) Operating room: Fluorescent lamps with power saving electronic ballast (2) Specified illumination on distributing board : Fluorescent lamp with power saving electronic ballast (3) Cellar : Fluorescent lamp with power saving electronic ballast (4) Outdoor lighting General lighting lamp : High pressure sodium lamps with high power factor type ballast Local lighting of conveyor, etc. : High pressure sodium lamps with high power factor type ballast (5) Road lighting High pressure sodium lamps with high power factor type ballast (6) Lighting in rest room : Incandescent type fluorescent lamp (7) Lighting of toilet, bathroom and canopy: Incandescent type fluorescent lamp (8) Emergency Incandescent lamps connected to emergency power source (AC) shall be installed to adequate numbers at the necessary place.

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Chapter 7 Electrical Equipment

7.1.3

Illumination (1) General indoor illumination shall follow the below standard or more than that.

Plant unit

Lux

Finex plant

100 - 150

Steel making shop 1) BOF 2) CCM

100 - 200 125 - 200

Rolling Mills Power plant & blower house

125 - 200 50 - 200

Air separation plant, compressor plant & pump house

100 - 150

By-product plant

100 - 150

Refractory & calcining plant

100 - 150

Foundry

100 - 150

Repair shop

150 - 300

Conveyor gallery & junction house

Electrical premise 1) Computer room 2) Control room 3) Switchgear room

50 - 100 300 - 500 200 - 300 150 - 200 30 - 50

Basement, oil cellar, gangway stairway Laboratory Stores Office(including conference room)

150 - 200 50 - 100 250 - 500 10 - 20

Outdoor stock yard, marshalling yard

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Partial illumination

Remarks

Chapter 7 Electrical Equipment

Place

Lux

Raw material handling yard

10 - 15

Switch yard

15 - 20

Roads

15 - 20

Blast furnace

100 - 150

Sinter plant

150 - 200 60 -150

Coke oven

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Partial illumination

Note

Chapter 7 Electrical Equipment

7.2 Grounding and explosion-proof facilities The method adopted for system as well as equipment earthing shall also comply with the relevant clauses of Indonesian Electricity Rules. All earthing shall be subject to the approval of the Chief Electrical Inspector, State Government. All earthing system shall be designed to ensure effective operation of protective gears in case of earth faults. The total earth resistance at any point of the earthing system for substations and main plant building shall not be more than one ohm as per Indonesian Standard. Galvanized MS flats/wire shall be used as earthing mat/wire. MS flats shall be galvanized and wires shall be galvanized . Normally sizes of galvanized MS flats/wires shall be selected from the sizes as indicated below unless higher sizes are required on specific consideration. 7.2.1 Earth lead The minimum size of galvanized MS flat earthing leads for neutral earthing of various transformers shall generally be as given below unless a higher size is required from the view point of higher available fault current: Generally G.S. strips/wires for grounding system are normally adopted in Industrial Plants in Indonesia. Copper strips/wires are generally not used, except for electronic earthing system (1)

(2)

11 kV, 6.6 kV, 3.3 kV .. side neutral of 33/11 or 6.6 or 3.3 kV transformer

380V side neutrals of 1600 kVA & 1000 kVA

..

6.6/0.433 kV transformers

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75 mm x 10 mm

75 mm x 10 mm

Chapter 7 Electrical Equipment

(3)

380V side neutral of 630kVA/ 6.6/0.433 kV transformers

.. 65 mm x 8 mm

7.2.2 Earth conductor The minimum size of galvanized MS flat earth conductors for main earthing ring, cross connections to main ring as well as leads taken to earth electrodes for various substations shall be as given below unless a higher size is required from the view point higher available fault level: (1) (2)

132 kV outdoor substation .. 65 mm x 8 mm .. 75 mm x 10 mm 33 kV, 11 kV and 6.6 kV substation/MCC

(3)

1000 kVA & 1600 kVA, 380V ..

65 mm x 8 mm

loadcentre substations (4)

630 kVA, 380V loadcentre .. 65 mm x 6 mm substations 7.2.3 Flat/wire earthing The minimum size of galvanized MS flat/wire for earthing of various equipment shall be as follows: (1)

Motor control centres, auxiliary power distribution boards etc. 1)

When located away from sending end switchgear and fed from:  

2)

1600 kVA transformer Less than 1600 kVA transformer

When located near sending end switchgear

7-91

.. ..

65 mm x 8 mm 50 mm x 6 mm

..

Same as far away from sending end switchgear

Chapter 7 Electrical Equipment

(2)

All main drive DC motors

..

50 mm x 6 mm

and 6.6 kV motors (3)

LT AC motors from 150 kW upto 220 kW

..

50 mm x 6 mm

(4)

LT AC motors from 110 kW upto 132 kW

..

40 mm x 6 mm

(5)

LT AC motors from 55 kW upto 90 kW

..

25 mm x 6 mm

(6)

LT AC motors from 15 kW upto 45 kW

..

25 mm x 6 mm

(7)

LT AC motors from 3.75 kW upto 11 kW

..

16 sq mm stranded

(8)

LT AC motors from 0.75 kW upto 2.2 kW

..

6 sq mm stranded

(9)

Control desk, control post

..

50 sq mm stranded

(10) Pushbutton station, limit switches, switch boxes, isolator and socket outlet upto 16A

..

6 sq mm stranded

(11) Isolator and socket outlet above 16A upto and including 100A

..

50 sq mm stranded

7.2.1 Explosion proof facilities Suppliers shall provide the electric equipment of explosion proof type that satisfies The following standard, if the electric equipment is installed at a dangerous place. Note) Related law: Law of industry safety and health article 23, regulation on industry safety

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standard article 333 and 334 and regulations of selection, installation and maintenance of explosion proof type electric machine, equipment and wiring. (1) Classification of dangerous places 0 class place It indicates a place where danger subsists continuously or for a long time. It is classified into inside of instrument and inside of equipment or pipe. 1 class place It indicates a place where danger is easily existent at normal operation. It is classified into surrounding of 0 class place, surrounding of supplying tools, surrounding of connection part that is opened for operation and surrounding of ventilation output hole. 2 class place Danger can be existent for a short time at abnormal state. (2) Principle of selecting explosion proof electric equipment Selection principle of electric equipment shall be as follows according to the class of explosion proof place with gas or steam. In the case of explosion proof place with dust, it shall follow item 2 of article 10 of chapter 3 in regulation on industry safety standard that deals with selection, installation and maintenance of explosion proof electric machine, equipment and wiring. 1) 0 class place ① Essential safety structure for explosion proof ② Specially designed structure of explosion proof that can be used in 0 class place 2) 1 class place ① Explosion proof equipment indicated at the above item 1) ② Pressure explosion proof structure ③ Oil immersed explosion proof structure ④ Specially designed structure of explosion proof that can be used in 1 class place. 3) 2 class place ① Same structure described at the above item 1) and 2). ② Safety explosion proof structure shall be used, if the electric equipment doesn’t cause arc, spark or high temperature at normal state. ③ Non-explosion proof equipment shall be used, if the maximum surface temperature of rotary machine without slip ring or commutator doesn’t exceed 80% of starting temperature at normal operation or if it tries to drop the high temperature. ④ Non-explosion proof equipment shall be used, if the maximum surface temperature of fixture lighting without switches like

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Chapter 7 Electrical Equipment

starter doesn’t exceed 80% of starting temperature at normal operation if it tries to drop the high temperature. But if there are switches in fixture lighting, it shall follow the structure described at the above item 1) or 2). ⑤ Specially designed explosion proof structure to be used at 2 class place

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Chapter 7 Electrical Equipment

7.3 Cable The size of wire and cable (1) The standard size of wire and cable 1) The size of wire and cable shall be as follows considering the convenience of maintenance. 2) Stripped wire ① Bare hard copper wire, round type hard drawn trolley wire : 8mmφ, 12mmφ 2 2 ② Grooved trolley wire : 110 mm , 170 mm : 110 mm2, 170 mm2, 240 mm2 ③ Rigid trolley wire 3) Copper Strip Width (mm) 25 50 75 100 125 150 Thickness (mm)

7.3.1

4

○

○

6

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

○

8 10 12

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Chapter 7 Electrical Equipment

4) Low voltage insulated wire, low voltage power cable and high voltage power cable shall follow the below table. Cross section (mm2) 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300 400 500 630

Low voltage insulated wire ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Low voltage power cable 1C

2C

3C

4C

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○

○ ○ ○ ○

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High voltage power cable

Extra high voltage cable

1C

2C

3C

1C

3C

○ ○ ○

○ ○ ○

○ ○ ○

○

○

○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○

○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○

Chapter 7 Electrical Equipment

4) Control cable

2C, 3C, 4C, 5C, 6C, 7C, 8C, 10C,12C, 15C, 20C, 24C, 30C, 1.5 mm2, 2.5 mm2, 4 mm2, 6 mm2, 10 mm2 Twisted Pair Cable Shielded Sheath Cable 5) Cabtyre Cable 1C, 2C, 3C, 4C, 5C, The size of conductor is same with 7.3.1 (1) 4). 6) Cable for wiring without insulators 2C, or 3C, 1.6φ, 2.0φ, 2.6φ 7) Communication cable 0.65φ or 0.9φ Aluminium Shield wire, 3P, 5P, 10P, 20P, 30P, 50P, 100P, 150P, 200P, 300P, 400P, 600P, 900P 8) Remote supervisory and control cable Same with 7.3.1 (1) 7), 8) Steel Corrugated, Anti-corrosion layer shall be coated. (2) Cable selection by cable current carrying capacity Cable should be selected by reduction factor due to multi cables laying multiplying with permissible current as shown below table 1) Table of permissible current Permissible current of power cable is as follows (Refer to table 1 ,2 and 3) 2)Ruction ratio of current by multi laying of cable(refer to table 4) (Table 1) Permissible current of 22kV power cable in case of laying in air or culvert 22KV Cable size Single core Three core 260 A 205 A 60 ㎟ 355 A 275 A 100 ㎟ 450 A 350 A 150 ㎟ 535 A 420 A 200 ㎟ 250 ㎟ 610 A 475 A 325 ㎟ 715 A 555 A 400 ㎟ 815 A 500 ㎟ 930 A 600 ㎟ 1,030 A

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Chapter 7 Electrical Equipment

(Table2) Permissible current of 22kV power cable in case of laying in air or culvert 22KV Cable size

Single core

Three core

260 A 355 A 450 A 535 A 610 A 715 A 815 A 930 A 1,030A

205 A 275 A 350 A 420 A 475 A 555 A

60 ㎟ 100 ㎟ 150 ㎟ 200 ㎟ 250 ㎟ 325 ㎟ 400 ㎟ 500 ㎟ 600 ㎟ (표 3)

Permissible current of CV cable in case of laying in air or culvert IEC standard (Ambient temperature: 40℃) Multi core cable

Cable size 1.5 ㎟ 2.5 ㎟ 4㎟ 6㎟ 10 ㎟ 16 ㎟ 25 ㎟ 35 ㎟ 50 ㎟ 70 ㎟ 95 ㎟ 120 ㎟ 150 ㎟ 185 ㎟ 240 ㎟ 300 ㎟ 400 ㎟ 500 ㎟ 630 ㎟

2 core 23 A 32 A 44 A 57 A 78 A 104 A 135 A 168 A 205 A 263 A 320 A 373 A 430 A 493 A 583 A 674 A

Single core cable 2 core closer

3 core 21 A 29 A 38 A 49 A 68 A 91 A 115 A 144 A 175 A 224 A 271 A 315 A 363 A 415 A 489 A 565 A

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146 A 182 A 220 A 282 A 343 A 397 A 458 A 523 A 618 A 712 A 855 A 985 A 1141 A

3 core closer

123 A 160 A 196 A 254 A 311 A 364 A 422 A 485 A 577 A 670 A 790 A 908 A 1047 A

3core (s=2d)

167 A 205 A 250 A 321 A 391 A 455 A 525 A 601 A 710 A 821 A 987 A 1140 A 1323 A

Chapter 7 Electrical Equipment

(Table 4) Reduction ratio by multi cables laying Circuit no. 1 2 3 4 Reduction 1 0.87 0.82 0.8 ratio

5 0.8

6 0.79

7 0.79

8 0.78

9 0.78

7.3.2

Discriminating method of cores of cable sheath and control cable (1) Standard colors of sheath of various cables for maintenance after foundation shall be as follows: Color of No. Use Note external skin Control and operation circuit 1 Control circuit device Yellow of motor, generator, transformer and thyristor Instrumentation and 2 Red digital circuit Main circuit power High and low power circuit, 3 source, telephone, Black telephone, interphone, guide communication and warning broadcasting Extra high voltage Black 154kV 4 Orange 30kV, Green 6kV 5

Remote control pilot wire and grounding line

Green

(2) The sheath of CV cable and outdoor overhead CVV cable shall endure

the cold outdoor temperature. (3) Discriminating method of the cores of control cable 1) Less than 7 cores 2 core : Black, White 3 core : Black, White, Red 4 core : Black, White, Red, Green 5 core : Black, White, Red, Green, Yellow 6 core : Black, White, Red, Green, Yellow, Brown 7 core : Black, White, Red, Green, Yellow, Brown, Blue 2) More than 8 cores Discriminating of the cores by printed number and color band

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Chapter 7 Electrical Equipment

The number of cores

Insulation color for each core

1 – 21

Black

1 ~ 21 (Same with the number of cores)

More than 22

White

1 ~ (the number of cores after exempting 21 of black cores)

Printed number

7.3.3 The selecting account of high voltage (or more than that) cable size shall be confirmed by KRI. 7.3.4

Cable mark The cable mark of power, control and signal cable shall follow the given standards.

7.3.5

Terminal connection box of control cable Relaying terminal box shall be used more than 600V class.

7.3.6

Grounding cable and grounding plate shall be connected by welding.

7.3.7

Applicable standards for multiple cores control cable It shall follow the below description. (1) Terminal connection box shall be installed at control place. (2) Connection terminal box 1) Connection terminal box shall be installed indoors. For easy maintenance, it shall be installed at the height of 500~700mm from the bottom.

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Chapter 7 Electrical Equipment

2) Connection terminal box shall be dust proof type and be made of (3)

(4) (5) (6)

(7)

7.3.8

more than 2~3mm thick steel plate. When putting in cables, cables shall be supported strongly by lock nut with rubber packing. Dust proof structure shall be applied. Space for distribution connection work shall be made in inside of box. One jack shall be installed at the bottom of box for portable telephone. Drawing that displays the arrangement of terminals shall be put into a transparent and thin case. And the case shall be put into a case holder. (Each terminal shall be indicated by a terminal signal.) Insulation of terminals shall be 600V class.

Application of multicore cable (1) Control voltage and rated voltage of cable shall be same. (Mixing AC and DC or the other voltage shall be exempted.) (2) Multicore cable that causes mutual induction shall not be made into one cable. (3) Multicore shall be separated from different cables according to their function. (4) The number of spare cores: The number of spare cores of cable shall be more than 10% of all. (Minimum 3 cores) (5) One kind of shuttle control function shall be located in the same cable. (6) Cable route related to control circuit shall not compose loop around the strong electric equipment. It shall be carefully designed to prevent the disturbances caused by induction.

7.3.9 Details of multicore control cable (1) 600V CVV shall be used. If it causes induction disturbance, CVV or metal shielded cable shall be used. 2 (2) The cross section of core is more than 1.5mm If there is vibration, it shall be more than 2.5mm2. (3) If description of the below is applied, metal shielded cable shall be used and its surface shall be coated with by vinyl or anti-corrosion material.

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Chapter 7 Electrical Equipment

① In case there is a danger of external damage in the indoor plant;

places with much oil like oil cellar; or near to rolling mills. ② Incase there is a danger of external damage in the outdoor plant and

wiring along facilities like conveyor or wiring in shallow wiring pit. 7.3.10 Design of wiring works (1) Summary Basic design of cable wiring shall follow this standard. (2) Underground cable line 1) Basic condition ① Laying depth The place of heavy pressure deeper than 1.2m The other places: deeper than: 0.6m 2) Cable to be used It shall be as follows satisfying related law and regulations. Classification Place Power cable

Control cable

Communication cable

General area

Bridge Building Vinyl Insulated Polyethylene Vinyl Sheathed Insulated Vinyl Cable (CVV) Sheathed Cable (CV)

Polyethylene Insulated Vinyl Sheathed Pair Cable (CPEV)

Places exposed to corrosive liquid (calcining plant)

Cross linked Polyethylene insulation, metal Sheathed Polyethylene Sheathed Cable

Polyethylene insulation, metal Sheathed Polyethylene Sheathed Cable

PE insulation, Metal sheathed, PE Sheathed Pair telephone Cable

Direct laying cable (including cables that is put into hume pipe)

Cross linked Polyethylene insulation, Polyethylene Sheathed Cable

Polyethylene insulation, Polyethylene Sheathed Cable

Note) The skin of cable shall be protected. The measure to prevent a damage of cable skin shall be needed

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Chapter 7 Electrical Equipment

3) Relation with facilities that are installed on ground. ① Relation with water pipe: All cables that are crossed with water pipes shall be checked one by one. Basically, it shall be classified as follows. (a) When they cross with drain pipe: Cables shall pass above the rain pipe. (b) When they cross with water pipe: Cables shall pass under the water pipe. (c) The distance between cables and pipes: More than 30cm 4) Installation of underground boxes ① Water leakage from water pipe shall be prevented, if possible. ② Drain facilities shall not be installed. ③ Zinc painting shall be used at bracket that is for indoor use. ④ Cable shall not be connected except underground box. 5) Plan of culvert or open ditch ① Culvert (a) The height of culvert shall be more than 2.0m. (b) Leachate shall flow into drain drum by adequate slope. Automatic drain pump shall be installed at drain. (c) The standard depth of drain drum shall be 60cm. (d) Metal material shall be inserted to prevent inundation. The depth of the metal material shall be same to the above item c. (e)This plan shall include an indoor lighting work. ② Open ditch (a) Open ditch shall be planned for motor wiring. Open ditch shall not be applied to hasty electric line from substation or to lines in plant, if possible. (b) Power cable shall not be installed inside open ditch. (c) Solid cover to prevent unallowable people from entering into it shall protect open ditch. (d) The top and side of open ditch shall be higher than ground level. (e) Others : Same with item ①. 6) Plan of piping ① Concrete hume pipes with socket and rubber packing shall be used. ② Base shall not be installed at piping line. Connection part shall be done with concrete.

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Chapter 7 Electrical Equipment

7) Direct laying method ① Trough shall be concrete. ② Trough shall be filled with sand. ③ In case of metal sheathed cable, the sheath of cable shall not be damaged in trough. ④ Vinyl tape that indicates the route of cable shall be installed under 300mm from the ground. ⑤ Supporter shall be installed at adequate place along straight cable line and at the corner of curve. (3) Conduit works 1)Basically hot dip galvanized rigid steel conduits shall be used. 2) Flexible conduits shall be used at an exposed place where external damage cannot be affected or can be easily detectable. (4) Cable Rack 1) Each cable rack for ultra high voltage, high voltage, low voltage of power, instrument, control should be exclusive. In case of exception, separators have to be installed for low voltage cables. 2) Inverter or vector drive cables shall be installed in exclusive rack or three phases have to be installed all together to minimize harmful effect. 3) The distance between cable racks should be more than 300mm. 4) Cable rack for higher potential should be arranged lower position. 5) When designing new plant, additional space should be considered for future revamping and improving. If there is no more space for cable when revamping, the other cable route has to be maintained. (5) Cable works 1) Cables shall be installed separately (extra high voltage, high and medium voltage, low voltage of power, instrument and control) and should be in accordance with following value of each cable rack Maximum value Occupying ratio Layer of section area 2 50% 2 50%

Use High voltage Low voltage

Instrument, control, communication

4

70%

In principle, cables in metal duct should not exceed 40% of duct area.

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Chapter 7 Electrical Equipment

2) Cable route should be described on cable schedule and route numbers have to be marked on cable rack that every cable be installed according to route number on cable schedule. 3) Extra high voltage cable shall not be exposed in plant. Extra high voltage cable shall be installed in duct wire pit that is made of sealed material. The minimum distance between ultra high voltage cable and other cable shall be 60cm. 4) Metal sheathed plate shall be installed between power cable and control cable where it is difficult to separate power cable like vertical area duct. 5) Cable shall not be connected to duct. 6) Cable embedded into concrete slab shall be protected by hot dip galvanized rigid steel conduits. The height shall not exceed 1.8m from the bottom of slab. 7) Metal duct is made from steel plate or light structural section steel. The thickness shall be as follows. But the thickness of plate that is exposed to outdoors shall be more than 2.6mm. Maximum width of Duct

Thickness of steel plate

By 200mm By 500mm By 750mm The more

More than 2.0mm More than 2.3mm More than 2.6mm More than 3.2mm

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Chapter 7 Electrical Equipment

7.4 Prevention of electric shock and accidents. 7.4.1 Limitation on exposure to electric charged parts and location of electric facilities (1) Electric facilities of extra high voltage 1) Electric facilities of extra high voltage of which current flowing part is exposed to outdoors shall be installed in only transformer room of substation. 2) Transformer bushing for indoor or outdoor use that is in receiving substation shall be elephant type or simple elephant type. Current flowing part shall not be exposed. 3) Electric facilities of high voltage of which current flowing part is exposed to internal facilities shall be separated from other facilities to prevent accident. Method of separation shall be as follows. ① The above equipment shall be installed in exclusive fireproof building. ② The above equipment shall be installed in a room that is isolated by exclusive non-flammable wall or iron net. ③ The above equipment shall be installed in exclusive electric cellars. ④ Exclusive door lock key shall be attached to the above electric room of extra high voltage. 4) Outdoor electric facilities shall be surrounded with outer fence. Voltage

Height (h) + Distance (d)

Less than 35kV

More than 5m

35kV ~ 160kV

More than 6m

More than 160kV

When it exceeds every10kV at 160kV and 6m, 12m shall be added.

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Chapter 7 Electrical Equipment

5) Elephant type shall be as follows.

6) Outside of indoor electric machines less than 3.3kV except some

equipment like condenser bushing shall be surrounded by steel plate. (2) High voltage electric facilities 1) Electric facilities of which current flowing part is exposed to outdoors shall be limited as follows. ① Transforming substation, transformer room, distribution line ② At a special place like travelling trolley wire and trolley rail of port crane, etc. 2) If receiving transformer is installed at outdoors, simple elephant type shall

be used. Current flowing part shall not be exposed. 3) Fences for outdoor facilities shall be applied as follows. ① Height (h)+Distance(d)=3m instead of item (1), 4) ② In case of elephant type, it is same to item (1), 6). 4) Electric facilities for indoor use of which current flowing part is exposed shall be installed at an electric room to prevent unallowable people from entering it except travelling trolley line of large capacity of crane. Fences that are described the above item 3) shall be installed. If overhead crane runs over high voltage electric facilities in which electricity flows at more than non-flammable and solid protective facilities shall be installed 30cm above the exposed current flowing part. The exposed parts shall be minimized. 5) Port crane travelling trolley line and rail shall be installed in exclusive pit that is made of steel and concrete. Separation cover of rubber material shall be protected.

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Chapter 7 Electrical Equipment

(3) Low voltage electric facilities 1) Low voltage electric facilities with exposed current flowing part,

2) 3) 4) 5)

6)

7.4.2

except trolley line of overhead crane and overhead distribution line, shall be installed at an electric room where unallowable people couldn’t enter and be protected by fences or iron net as follows. h + d ≥ 2m instead of item 4) of (1). All the electric facilities with exposed current flowing shall not be installed at outdoors. But, trolley line of crane is exempted. OW insulated line or something like that shall be used at overhead distribution line. Running trolley cable and trolley rail for port crane are same to item 5) of (2). More than 1m space shall be made in front of exposed control panel and switch to protect passengers from electric shock. Hand rails shall be installed in front of panel in narrow places such as crane electric room. The bus and branch of open panels shall be insulated with coating according to voltage, even if they are installed at electrical room.

Limitation on the use of switching apparatus (1) Switching equipment for extra high voltage 1) Except expansion or modification under 3.3KV. Switch cubicle shall

be enclosed unit type 2) Grounding switch shall be installed at switch equipment of more than 3.3kV feeder to discharge charging potential. 3) Switching equipment of more than 3.3kV shall be controlled by motor. (2) High voltage switching equipment 1) When the existing equipment does not require expansion or modification, attaching type high voltage disconnecting switch shall not be used. If establishing bare type disconnecting switch is to be used, pilot lamp or interlock equipment that indicates the state of breaker shall be installed at a place in which people can easily see. 2) Incoming disconnecting switch of Enclosed type unit switch cubicle shall be connected to related breaker. Operating rod while the door of switchboard is being closed shall be able to operate the disconnecting switch. 3) Section switch that is installed at high voltage distribution line shall be able to operate at rated load of current state.

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Chapter 7 Electrical Equipment

(3) Disconnecting switch at primary side of transformer

When disconnecting switch is installed just at the primary side of transformer, it shall control exciting current. Disconnecting switch shall be operated with breaker of secondary side of transformer together. (4) Low voltage switching equipment 1) Covered knife switch shall not be used at DC 220V and AC 440V 2) Surface attaching type MCCB shall be installed at steel box or board in dead front type panel. If it is installed at electric room, it shall be exempted. 7.4.3 Danger indication Red pilot lamp that indicates the live state of crane trolley cable shall be installed at both ends of crane trolley cable and section breaker. 7.4.4 Plug-socket (1) Plug-socket of mobile tools shall have exclusive ground pole and MCCB. The detailed structure of Plug-socket shall be indicated in parts. (2) Leakage breaker shall be installed at plug-socket of tools that are operated by motor, mobile pump and mobile blower to prevent shock. In this case one leakage breaker can be used to connect multiple plugsockets. 7.4.5

Prevention standard of accident at electric wiring work (1) Structure of duct 1) The area of inside duct shall be basically less than 0.5㎡ for each

group. 2) Group can be made as follows according to the use of duct. ① Specially high voltage cable ② High voltage cable ③ Low voltage power cable ④ General control cable ⑤ Weak signal circuit cable: Basically shielded cable ⑥ Analogue circuit cable: Same with the above Note) (1) Items ①,②,③,④ can be separated by steel isolator in horizontal duct. (2) Wiring working of telephone in plant shall not use duct but conduit. (3) If necessary, item ④,⑤, and ⑥ can be installed

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at the same duct. But if possible they shall be separated from each other. (4) When they are installed at a rack, extra high voltage cable shall be located in the lowest rack and analog cable shall be located in the highest rack.

3) Vertical duct ① The side of vertical duct shall be expanded plate and wall side

shall be steel plate. But in a bad environment like mill yard or fire fearing place, both sides shall be made of steel plates. ② Top and bottom cable of vertical duct shall be fastened with cleat. Gaps shall be tightly covered by steel plate. Cable piercing part shall be managed with short conduits and the others shall be covered by steel plate. ③ Sand sacks shall be piled up beside the top and bottom of vertical duct. (2) Upstairs and downstairs part of duct for distributing board and outgoing point 1) Pit that is in bottom of distributing board or controlling board shall not be installed in direct bottom. 2) Cable and wire shall go up through conduit. Conduit shall be surrounded by steel plate that separates the bottom of distributing board and pit.

(3) Oil cellar 1) Oil cellar shall not be connected to cable culvert. 2) The wiring going in-and-out oil cellar and internal wiring of oil

cellar shall be managed with conduits. (4) Water drain of culvert for cable wiring 1) At an adequate place of culvert or tunnel, a drainage pit (volume: more than 0.4㎥) shall be installed. Adequate inclination shall be done for pit. 2) Automatic drain pump shall be installed at each pit.

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Chapter 7 Electrical Equipment

7.4.6 Fire prevention measurements During the detailed design of electric facilities, supplies shall take following measures to protect fire of cable. (1) Cable that is installed near to the door of electrical room shall be filmed by fireproof material. (2) If necessary, noninflammable cable shall be used. (3) Independent floor (subsidiary floor), which can be used to install cable beneath the electrical room, shall not be installed. (4) Fire fighting film shall be installed to the fire prevention division. (5) Fire fighting door shall be installed at in-out culvert of electric room. (6) Gaps of in-out door at upstairs duct shall be covered by steel plate. (7) Fire alarming equipment shall be installed in cable culvert.

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Chapter 7 Electrical Equipment

7.5 Lightning Protection System Outdoor switchyard shall be protected against direct lightning stroke by means of overhead shielding wires. Wherever required vertical air terminations (masts) shall also be provided on the substation gantry columns. Normally Shielding wires shall comprise 7/ 3.15 mm galvanized steel wire of 110 KG. The minimum size of horizontal conductor normally used as air termination sha ll be 25 x 4 mm galvanized MS flat. The same for down conductor from air termination to earth electrode shall be 40 x 6 mm galvanized MS flat.

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Chapter 7 Electrical Equipment

7.6 Layout Clearance and Safety Requirements 1)

For every electrical switchboard, control panel, motor control centres etc, that requires back access, the space behind the equipment shall generally be around 1000 mm but in no case less than 762 mm. The space provided shall be adequate to permit at least 90 degree opening of doors or hinged panels. In cases where back clearances are provided, there shall be a passage–way from either end of the equipment clear to a height of 1800 mm. Where the equipment are not required to be attended from the back, the equipment shall be placed along the wall/structure having clearances less than 200 mm.

2) For all switchboards, control panels, motor control centres etc a clear space of not less than 1000 mm shall be provided in front of the equipment. In cases where the equipment is provided with drawout units, a minimum clearance of 2000 mm shall be provided. 3) For all electrical equipment a minimum clear head-room of 500 mm shall be provided. 4) In case of transformers located inside fully enclosed cells, free space around the transformer shall be not less than 1000 mm. The actual spacing, if required, may be increased depending on the need to have proper access to the accessories mounted on the transformer tank. 5) For indoor type ONAN transformers, fire separating barrier of 355mm thick brick wall or 230mm concrete wall up to the roof shall be provided in between two transformers. 6) For transformers located outdoor the fire separating barrier shall be of 355 mm thick brick wall. 7) For all the transformers located in cells having front covered by expanded metal structure, a clear space of not less than 1,250 mm shall be provided between the transformer and the expanded metal structure.

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8) The clearance provided between the highest point of the transformer considering the mountings on the top of the transformer tank and the ceiling of the transformer cell shall be sufficient to remove mountings like conservator etc. However, this clearance shall not be less than 500 mm in any case. 9) For dry type transformers with enclosure having degree of protection IP20 the clearances shall be provided according to Clause 1.1, 1.2 and 1.3 mentioned above. 10) All outdoor substations shall be provided with at least 2000 mm high masonry wall having galvanized steel spikes on top. 11) All motors located away from the feeding end control panels, for which control desks/posts are not within visible distance, shall be provided with readily accessible and easily operable, locally mounted lockable type `stop’ push-buttons in the control circuits. 12) Resistors used for motor controls, when not installed in motor control centres/control panels, shall be so located and guarded as to prevent accidental contact with persons or combustible materials. 13) All electrical equipment having operating voltages, 415 V and above, shall be provided with danger boards of approved type and shall be affixed permanently in a conspicuous position. Where a group of equipment is located within a switch/control room or within a fenced area, the board shall also be fixed at the entrance. Shock treatment charts shall be provided near such equipment for first-aid during shock-treatment. The board and the shock-treatment chart shall be in three languages viz., English, Hindi and State language. 14) All moving parts of equipment which are exposed and are liable to cause hazard to the operation/maintenance personnel shall be suitably protected by metallic guards. 15) A minimum clearance of 2000 mm shall be provided between high voltage and low voltage switchgear panels while installing in the same building. 7-114

Chapter 7 Electrical Equipment

16) 750 mm wide rubber mats of thickness not less than 6 mm shall be provided in front of all switchboards for personal safety. The rubber mats shall be tested for applicable voltage grade. 17) Open type power equipment or busbars shall not normally be installed inside switch/control rooms. However, when such equipment are to be provided inside, these shall be properly enclosed by expanded metal fencing Open type busbar inside the switch/control room shall generally be laid in the cable cellar/basement and shall run at a height of 2000 mm and above and properly guarded by expanded metal enclosure. 18) All switch/control rooms as well as the substation building shall have minimum two entry/exit doors. These exits shall be provided with double door arrangement to prevent leakage of ventilation air which is generally kept slightly above atmospheric pressure. The cable cellars and basement shall also be provided with minimum two entry/exit doors. 19) For safety and clearances in substations, overhead transmission lines standards as enclosed are to be referred.

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8.0 Test and inspection standards The supplier shall offer documents for test and checking (testing items, testing machines, testing and testing method) and be confirmed by KRI. The supplier shall perform test and offer the test result when the supplier provides the machinery. 8.1 Test and inspection at manufacturing plant 8.1.1 The supplier shall perform test and checking for important parts by itself during manufacturing or after manufacturing. For items ordered from outside suppliers, sub-maker or the supplier shall perform test or checking and make test result. 8.1.2

Final test The supplier shall perform an assumed assembling test or an ability test after manufacture. Testing items shall be as follows. (1) Appearance test (2) Structure test (3) Shape size test (4) Operation test 1) Instrument operation test 2) Electric operation test (5) Insulation resistor test 1) Main circuit 2) Operation circuit and control circuit (6) Withstand voltage test (7) Operation test of displaying equipment (8) The others

8.2 Attending inspection 8.2.1 Test during manufacturing Inspector from KRI or technician who is requested by KRI shall check all the manufacturing procedure like material to be used, working schedule during manufacturing. If the inspector requires to see necessary data for checking or to perform a test, the supplier shall be cooperative.

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8.2.2

Manufacturing plant test after manufacturing After the manufacturer passed final manufacturing test and inspect, calling witness inspection before offering, they shall pass a test provided by inspector from KRI or technician who is requested by KRI. Testing items shall be same with Paragraph 8.1.2. If it is necessary to confirm ability or characteristics, etc., supervisor shall require to perform other tests.

8.2.3

Supervision test shall be exempted according to the characteristics of machines and by decision of supervisor or be tested by one who is requested by supervisor.

8.3 Test by authorized organization The manufacturer shall pass the regulation of authorized organization. The manufacturer shall pay for the cost 8.4 Delivery test It shall be performed after the product is transported to a place KRI indicated. When the product passes the test described below, it is recognized to be delivered. 8.4.1 Appearance test 8.4.2 Quantity check 8.5 Performance test After installation following tests shall be performed under the supervision of supplier. The result shall be confirmed by KRI. Details shall be discussed with KRI before testing operation. 8.5.1 PAT (Preliminary Acceptance Test) PAT is a test that is performed to find the performance of entire function after installation of unit equipment. The test shall be done with a method that KRI confirmed. Under no load condition, the supplier shall test the following items with inspector from KRI. (1) Insulation endurance test (2) Insulation resistor test (3) Line constant test (4) Line test(Inspection of laying state, inspection of connection state) (5) Phase confirmation test (6) Independence test for each equipment (7) System integration test under no load

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(8) Condition of passing 1) Whether it performs according to the way and purchase

specification, which KRI confirmed. 2) Whether it performs the items what KRI and the supplier has agreed. (9) After the test the supplier shall provide PAT REPORT. 8.5.2 FAT (Final Acceptance Test) (1) FAT shall be performed after PAT. It is performed after adjusting in detail under on-line state of real load. (2) To find if it satisfies functions written in contract, the test shall be done according to FAT documents written by supplier. 8.6 Manufacturing inspection Manufacturing inspection of electric goods shall be done according to the inspection standards of KRI. (1) Transformer : (2) Panel : (3) Motor (4) Generator (5) Communication equipment

: : :

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Chapter 8 Instrumentation

8-1

Chapter 8 Instrumentation

Contents 1.0

General ......................................................................................................................

4

2.0

Design conditions ....................................................................................................

8

3.0

Engineering services ...............................................................................................

9

4.0

Painting and coloring standards .........................................................................

9

5.0

Packing standards ....................................................................................................

9

6.0

Design criteria ........................................................................................................

10

6.1 General .................................................................................................................

10

6.2 General standards ............................................................................................

10

6.3

6.2.1

Protection structure ..............................................................................

11

6.2.2

Explosion proof structure .....................................................................

12

6.2.3

Noise .......................................................................................................

12

6.2.4

Sources of electricity ..............................................................................

12

6.2.5

Signal specification .............................................................................

13

6.2.6

Effect of electromagnetic field .............................................................

13

6.2.7

EMC; Electromagnetic Compatibility ................................................

13

6.2.8

Accuracy ...................................................................................................

13

6.2.9

Material ....................................................................................................

14

6.2.10

Surrounding environment..................................................................

14

6.2.11

Name Plate.............................................................................................

14

6.2.12

Environmental pollution ....................................................................

14

6.2.13

Others .....................................................................................................

14

Field instruments ...........................................................................................

15

6.3.1

General instruments ..............................................................................

15

(1)

Temperature instruments ..............................................................

15

(2)

Flow instruments ............................................................................

17

(3)

Manometers ......................................................................................

20

(4)

Level instruments ............................................................................

22

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Chapter 8 Instrumentation

6.3.2

Control Valve ........................................................................................

24

6.3.3

Special instruments .............................................................................

26

(1)

General ............................................................................................

26

(2)

Protecting from radiation ............................................................

26

(3)

Thickness gauge using radiation and X-Ray generator .........

27

(4)

On-line inspection equipment .....................................................

27

(5)

Weigher ...........................................................................................

28

6.4 Panel instrumentation .......................................................................................

29

6.4.1

Recorders and indicators ......................................................................

29

6.4.2

Controller ...............................................................................................

29

6.4.3

Annunciator ............................................................................................

29

6.5 Control System .................................................................................................

30

6.5.1

Distributed Control System ...............................................................

30

6.5.2

Instrumentation panel .........................................................................

32

6.5.3

Relay panel ............................................................................................

34

6.6 Utility for instrumentation ...............................................................................

34

6.6.1

7.0

Sources of electricity ............................................................................

34

(1)

General ..............................................................................................

34

(2)

Uninterruptible power supply ...................................................

35

(3)

Power distribution panel .............................................................

36

6.6.2

Sources of instrument air ....................................................................

37

6.6.3

Hydraulic source ....................................................................................

38

6.7 Others ...................................................................................................................

38

6.7.1

Control room & panel room ...............................................................

38

6.7.2

Grounding ...............................................................................................

39

Test and inspection standards ...............................................................................

40

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Chapter 8 Instrumentation

1.0 General 1.1 Scope of application It shall be applied to all instrumentation equipments that are supplied to KRIIndonesia. 1.2 Scope of supply 1.2.1 Scope of supply (1) Instruments and control system (2) Consumables and spare parts 1) Consumables ① Recording paper ② Recorder pen and ink ③ Lamp and fuse ④ Relay 2) Spare parts ① Distributed control system - Central Processing Unit Module: 1 set (If necessary) - Memory Module: 1 set (If necessary) - Communication Module: 1 set (If necessary) ② Input/output card: 10% of each kind ③ Detecting cell of analyzer: 1 set for each kind(if necessary) ④ Supply quantity except the above instruments shall be discussed between KRI and the supplier. 3) The quantity of consumables shall be determined after discussion. For the spare parts, the supplier shall provide determined quantity.. (3) Design and engineering The supplier shall perform the following works required, construction operation and maintenance. 1) Design to install the supplying equipments in field 2) Design to supply utilities (after take over point) 3) Providing list of tools and materials with general specification that KRI shall provide 4) Providing drawing and data (4) Supervising field installation The supplier shall supervise field installation.

8-4

Chapter 8 Instrumentation

1) Technical description and advice for installation 2) Directing and advising about transport, loading and unloading. (5) Commissioning and adjustment

After the installation the supplier shall provide documents of commissioning method to KRI. Supervisor shall direct and advise about commissioning. (Preliminary Acceptance Test, Final Acceptance Test) (6) Inspecting, packaging and transporting the supplying equipments Inspection and packaging of supplying equipments shall follow 7.0 Standard of test and inspection and Part 5 Painting · Coloring · Packaging, ISZ-1. Transport shall be done on a road KRI indicates. (7) Instruction and training The supplier shall include documents of instruction and training for maintenance in contract specification. The supplier shall provide instruction and training according to the documents. Personnel who is to be trained and period shall be determined after discussion. --- > shall be refer to term of conditions which stated in the contract. (8) The supplier shall provide list of special measuring equipment and tools that are necessary in commissioning. The method of supplying them shall be determined after discussion. --- > shall be refer to term of conditions which stated in the contract. (9) The supplier shall provide list of special cable of which domestic supply is impossible. The method of supplying it shall be determined after discussion. --- > shall be refer to term of conditions which stated in the contract. (10) The supplier shall provide manual, drawing and data for construction, commissioning, operation and maintenance. Materials and services out of the range of supply The following shall be done by KRI except what is directly done by engineers of the supplier. (1) Foundation and installation work for instruments and control system (2) Installation work for utilities’ supply that is necessary for main equipments (3) Telephone and local broadcasting facilities (4) Preparation of tools, materials that are necessary for field installation (5) Lighting facilities for indoors and outdoors, cooling and heating facilities, indoors and outdoors hydrant, water supply and general drainage facilities (6) Unloading the purchasing goods and storing of them (7) Preparing general tools and materials that is necessary for test and operation (8) Staffs for commissioning 1.2.3 When the range of supply is required to be classified, it shall be determined after discussion.

1.2.2

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Chapter 8 Instrumentation

1.3 Drawings and documents The supplier shall provide drawings and documents that are described on ISZ-1 Part 2 according to schedule agreed with KRI. Especially, the following items shall be added to those drawings and documents. 1.3.1 When submitting an estimation (1) Specification of each equipment (2) Price list of each equipment (3) Table of the scope of supplies (The supplier and KRI) (4) Work schedule (5) Document of control system description (6) Flow sheet (7) Input/output List and the number of entire quantity (8) Control Room Layout and Panel Room Layout (9) Panel drawing (If necessary) (10) Desk drawing for operation (If necessary) (11) Drawing of utility (Power, instrument air and so on) (12) Interface specifications of system inside and specifications for interface with other systems (Data link method) (13) Surrounding condition for installation (14) List of consumables and spare parts and their price (15) Equipment that is needed for commissioning (16) Document for training plan (17) spare parts possessing period for supplying equipment (18) Catalogue of each equipment (19) Memory map of Distributed Control System (If necessary) (20) Other necessary data 1.3.2

When contracting It is same with the list that is made when submitting an estimation sheet. If changes are required, it is determined after discussion.

1.3.3

At the time of basic design (1) Control System Configuration (2) Control Room & Panel Room Arrangement (3) Flow Sheet (4) Interface specification of system inside and specifications for interface with other systems (Data link method)

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Chapter 8 Instrumentation

1.3.4

At the time of detail design (1) Design of instrumentation equipment 1) Document of detail description of system 2) Detail flow sheet 3) Design data of orifice plate, control valve and control logic 4) Calculation data of required utility quantity 5) Interface diagram for process input/output (Schematic drawing) 6) Interface specifications of system inside and specifications for interface with other systems (Data link method) 7) Operation screen of Human Machine Interface of control system 8) Other necessary data (2) Design for construction 1) Instrument Location Plan 2) Instrument Wiring Plan 3) Instrument Air Piping Plan 4) Control Room & Panel Room Arrangement 5) Instrument Installation Detail (Hook-up) 6) Instrument Cable Schedule 7) Instrument Interconnection Diagram 8) Other necessary data

1.3.5 At the time of shipment (1) Document for shipment (2) Document of test result before shipment 1.3.6

At the time of adjustment (1) Adjustment manual (Including trouble shooting) (2) Document of adjustment result

1.3.7

At the time of PAT/FAT (1) Test manual (2) Document of test result (3) Final drawings and documents Final drawings and documents shall include revised parts after installation and commissioning. The list and quantity of drawings and documents to be submitted shall be made based on Part 2, ISZ-1.

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Chapter 8 Instrumentation

1.3.8

For maintenance and operation (1) Operation manual (2) Maintenance manual

1.3.9

Others All the drawings and documents shall be made with material of good quality. They shall be made according to Part 2, ISZ-1.

2.0 Design conditions 2.1 General Design conditions shall follow the purchase specification and Part 4, ISZ-1. 2.2 Design standards Design, manufacturing, test and inspection of instruments and control system shall follow Chapter 8 of ISZ-2 and construction and inspection standard of KRIIndonesia. Items that are not included in the above standards shall follow the below standards.

2.2.1 IEC (International Electrotechnical Commission) 2.2.2 ISO (International Organization for Standardization) 2.2.3 KS (Korean Industrial Standard) 2.2.4 JIS (Japan Industrial Standard) 2.2.5 ISA (Instrument Society of America) 2.2.6 ANSI (American National Standards Institute) 2.2.7 DIN (Deutsche Normen) 2.2.8 JEM (The Standard of Japan Electrical Manufacturer Association) 2.2.9 Maker's Standard

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Chapter 8 Instrumentation

3.0 Engineering services Part 3 Engineering, ISZ-1 shall be the standard.

4.0 Painting and coloring standards Painting and coloring of instruments shall follow Part 5 Painting · coloring · packaging, ISZ-1.

5.0 Packing standards Instrumentation equipment shall be packed and protected by external dampness and impact so that they are not damaged during transport. When storing the instrumentation equipments at the field, corrosion shall not occur. The other details shall follow Part 5 Painting · coloring · packaging, ISZ-1.

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Chapter 8 Instrumentation

6.0 Design criteria 6.1 General 6.1.1

International standard shall be noted at document of estimating price for instrumentation equipment.

6.1.2 When some items are outside of this standard, they shall be confirmed by KRI. 6.1.3

Definition In this standard, instrumentation equipments indicate all kinds of instrument and system such as general instrument, control valve, special instrument, panel instrument and control system. (1) General instrument indicates temperature instrument, flow instrument, pressure instrument and level instrument that measure the state of process operation. (2) Control valve is equipment that gives control value to process and maintains the state of process as desired one. (3) Special instrument indicate equipment or system for controlling special process such as measuring equipment that make use of radiation and weighing system. (4) Panel instrument indicate instruments, installed in panel, that inspect and control the operation state of process. (5) Control system indicates controller and related panels for control of process that perform control program running, displaying process operation state and responding control order by operator. It is composed of Distributed Control System, instrumentation panel and relay panel.

6.1.4

Approval (1) All the documents shall be approved by KRI. (2) Even though documents and drawings are approved by KRI, the supplier shall have responsibility to provide good quality and performed – warranties of instrumentation equipments that are contracted.

6.2 General standards The supplier of instruments and control system shall provide goods that satisfy the following specification.

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Chapter 8 Instrumentation

6.2.1

Protective structure The supplier shall consider the environmental condition where instruments and control system are installed. Applicable protective structure shall be as follows.

IP□□ Symbol 1: :Protection degree 대한 from water 제 2기호 물의 침투에 보호infiltration 정도 Symbol 2: :Protection degree from human body정도 or solid 제 1기호 인체, 고형물에 대한 보호

Symbol 1

Degrees of Protection

0

No special protection

1

A large surface of the body, such as a hand (but no protection against deliberate access). Solid objects exceeding 50mm in diameter

2

Fingers or similar objects not exceeding 80mm in length. Solid objects exceeding 12mm in diameter

3

Tools, wires, etc., of diameter or thickness greater than 2.5mm. Solid objects exceeding 2.5mm in diameter

4

Wires or strips of thickness greater than 1.0mm. Solid objects exceeding 1.0mm in diameter

5

Ingress of dust is not totally prevented but dust does not enter in sufficient quantity to interfere with satisfactory operation of the equipment

6

No ingress of dust

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Chapter 8 Instrumentation

Symbol 2

Degrees of protection

0

No special protection

1

Dripping water (vertically falling drops) shall have no harmful effect.

2

Vertically dripping water shall have no harmful effect when the enclosure is tilted at any angle up to 15o from its normal position.

3

Water falling as a spray at an angle up to 60 o form the vertical shall have no harmful effect.

4

Water splashed against the enclosure from any direction shall have no harmful effect.

5

Water projected by a nozzle against the enclosure from any direction shall have no harmful effect.

6

Water from heavy seas or water projected in powerful jets shall not enter the enclosure in harmful quantities.

7

Ingress of water in a harmful quantity shall not be possible when the enclosure is immersed in water under defined conditions of pressure and time.

8

The equipment is suitable for continuous submersion in water under conditions which shall be specified by the manufacturer Note. Normally, this will mean that the equipment is hermetically sealed. However with certain types of equipment it can mean that water can enter but only in such a manner that it produces no harmful effects.

6.2.2

Explosion proof structure If the instruments are installed at a hazardous area, the instruments shall be explosion proof. Details shall follow Part 6, ISZ-2.

6.2.3

Noise Noise occurred from instruments and control system shall be less than 80dBA.

6.2.4

Sources of electricity (1) The power of instruments and control system shall be AC220V 50Hz or AC110V 50Hz. If dangerous accidents are expected like electricity failure, battery back-up system shall be prepared. (2) Voltage to instrument and drive solenoid valve shall be 24V DC or

AC220V 50Hz.

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Chapter 8 Instrumentation

6.2.5

Signal specification (1) In case of an analog signal, electric signal shall be 4 ~ 20mA DC or 1 ~ 5V DC and air pressure signal shall be 0.2 ~ 1.0 kg/cm2. (2) Digital signal shall be dry contact. Control voltage shall be 24V DC or AC220V(110V), 50Hz.

6.2.6 Effect of electromagnetic field If instruments and control systems are affected by electromagnetic field that occurs from process, the supplier shall provide KRI with instruments and control system that is not affected by electromagnetic field, or provide preventive measured and be approved by KRI. 6.2.7

EMC; Electromagnetic Compatibility To prevent industrial hazard caused by communication interference and malfunction of machines from unnecessary electromagnetic wave from electric or electronic machines, the supplier shall provide instruments and control system that are adequate for EMI (Electromagnetic Interference) and EMS (Electromagnetic Susceptibility). The supplier shall pass the EMI and EMS tests performed at Radio Research Laboratory and provide an EMC eligibility certificate.

6.2.8 Accuracy The accuracy of instruments and control system shall satisfy the following standard. The accuracy of instruments and control system that are not defined shall be confirmed by KRI. - Transmitter (Pressure/Flow/Diff. pressure/Temperature) : ±0.1 % of -

calibrated range or better Hysterisis of control valve: 1.0% of operated range or better Linearity of control valve: ±1.0% of full scale or better Electro-pneumatic converters : ±0.5 % of span range or better

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Chapter 8 Instrumentation

-

Controllers : ±0.25 % of span range or better Panel mounted indicators or recorders : ±0.5 % of full scale or better

-

Pressure gauges : ±1.0 % of full scale or better Temperature gauges : ±1.0 % of full scale or better Digital indicators : ±0.1 % of full scale or better Pressure switches : ±1.0 % of calibrated range or better

6.2.9

Material The supplier shall determine the material of wetted part that are adequate to the characteristics of process fluid and prevent it from bad performance and corrosion.

6.2.10

Surrounding environment The supplier shall provide instruments and control system that is adequate to surrounding environment for the following items that KRI- Indonesia suggests. - The accuracy of power

- Supplying pressure of instrument air - Oscillation - Dust - Corrosive gas - Salt 6.2.11 Name plate Name plate of panel shall be made of composed acryle stainless steel plate and be attached to front top of panel. Black characters shall be written on white background. 6.2.12 Environmental pollution Materials like mercury shall not be used in the instruments because it can pollute the environment and if such materials are to be used in the instrumentation, it shall be approved by KRI. 6.2.13 Others (1) Instruments and control system shall be designed considering reliability, utilization, maintenance and extensibility. (2) Instruments and control system shall be easily connected to process computer and electric system through open area network in the future.

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Chapter 8 Instrumentation

(3) If the process fluid is oxygen or acetylene, all the instruments and its

(4) (5)

(6)

(7)

subsidiary material shall be degreased (oil-less, oil cleaning) and then supplied. And flange shall not be painted. Each circuit of electronic machine shall be united. Plug in type circuit shall be supplied for easy exchange. Instruments and control system shall be made from a reliable maker, which has an experience about steel process. The supplier shall discuss with KRI when selecting a maker. Bypass line, block valve and bypass valve shall be installed for quick maintenance and emergency operation to prevent disorder of instruments from affecting process operation. Diameter of bypass line is same with that of main line. When flow meter requires a straight line in front and back of instrument, straight line shall be prepared.

6.3 Field instruments 6.3.1

General instruments (1) Temperature instruments 1) When measuring temperature, thermocouple, RTD (resistance temperature detector) and radiation pyrometer shall be used. But in the case of field indicator, filled thermal elements can be used. 2) Temperature instruments shall be selected considering the state of process. 3) The other temperature instruments shall be selected considering the following. ① Direct operation type indicator or controllers of field installation type ② In the case of temperature measuring which is specially indicated 4) If the range of measuring temperature is not specially indicated, the following table shall be applied: Temperature

℃

Device Thermocouple(R)

0~1200, 0~1400, 0~1600, 400~1400

Thermocouple (K)

0~300, 0~500, 0~800, 0~1000, 500~1000

RTD (resistance temperature detector)

-200~100, 0~350, 0~650

Radiation pyrometer

0~400, 400~800, 600~1200, 800~1600

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Chapter 8 Instrumentation

5) The length of thermocouple

If it is not specially indicated, it shall be applied by following the table. Kind of thermocouple

Standard length(mm)

R

800,900,1000,1200,1400,1500,1700

K

500,600,750,1000,1200,1500

6) Protecting tube ①

In the case of R Type thermocouple, double walls’ protecting tube shall be used. Internal material shall be high aluminum, high aluminum ceramic and material of same or better quality. But if delay time is long, single wall’s protecting tube can be used.

②

Even though the protecting tube is damaged, measuring material shall not be leaked. ③ The flange of following table shall be used in piping of flowing fluid that exceeds 200℃ and 2 kg/cm2 (196 KPa). Screw type shall be used at lower temperature and pressure than the above type.

Flowing fluid

Flange standard

Water of more than 10kg/cm2 steam, and liquid ammonia and liquid nitrogen

ANSI #300 or

Oxygen

ANSI #600 or

SNI ( )

SNI ( ) Others

Diameter 15A, 20A, 25A, 40A, 50A

15A, 20A, 25A, 40A, 50A

Remark Basically insertion length shall be more than 15 times of tube’s diameter at metal tube and 10 times at non-metal tube’s diameter.

ANSI #150 or SNI ( ) ④

Considering the surrounding environment, thermocouple extension wire shall be heat proof and water proof if necessary. 7) Radiation pyrometer ①

Linearizer shall be adopted for radiation pyrometer ② The measuring range of radiation pyrometer measures shall be narrow. ③ It shall have functions like cooling, purging and blocking the external light.

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Chapter 8 Instrumentation

④

Function of radiation rate adjustment shall be possessed. Adjustment shall be possibly done in instruments room remotely.

⑤

If the temperature changes severely, signal smoothing equipment shall be possessed. ⑥ If necessary, noise filter or measuring method that is protected from noise shall be taken into consideration 8) Line scanning pyrometer ① View angle shall be wider than 60° ② Radiation rate adjustment shall be possibly done remotely at scan processor. ③ Period of refreshing display and data shall be able to change. ④ Detection of edge part shall be automatically done at scan processor in response with width change. ⑤ Storage capacity of scan data shall be more than the following value. - Coil: 4000 ea - Hard disk capacity: 10 GB (Min.) or better -

Hard disk user working space: 1 GB (Min.) or better

⑥

1, 2 and 3 dimensional analyses shall be possible with data display. ⑦ Protection facilities shall be provided. (2) Flow instruments 1) Type If the type of flow instrument is not specially defined, it shall be differential pressure type. But the following type of flow instruments can be selected by fluid condition 2) Differential pressure type flow meter ① Orifice Plate - Standard orifice plate shall be applied. -

Method of Extracting differential pressure from orifice plate shall be as follows.

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Chapter 8 Instrumentation

Inside diameter (mm)

Type

200>D50

Corner tap or flange tap

760>D200

Vena contract tap

D760

Vena contract tap with Equalizing pipe

-

Design and calculation sheet of orifice plate including the following items shall be provided. Name of fluid Density: kg/Nm3 Inside diameter: mm Maximum flow rate: Nm3/h, m3/h, kg/h Normal flow rate: Nm3/h, m3/h, Kg/h Differential pressure (maximum): mm Aq Normal pressure: kg/cm2 & Pa or mmAq Normal temperature : ℃ Relative humidity: %(only for Gas) Viscosity: CP Flow rate coefficient Expansion compensating coefficient Diameter of orifice bore: mm Pressure loss: mm Aq Reynolds number (Calculated value) The position of tap: mm Thickness of orifice plate: mm Error anticipated: Nm3/h or % Contraction ratio:

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Chapter 8 Instrumentation

- The material of orifice plate shall be selected from the following table. Stainless steel 304

Air of normal temperature, Non corrosive gas, general fluid

Stainless steel 316

Corrosive fluid

-

-

②

Valve for differential pressure extraction shall apply flange or screw type. But in the case of high-pressure liquid or steam, welding type is allowed. Lubricated cock shall be used at Finex off gas, LD gas and mixed gas. If necessary, drain hole or vent hole shall be designed at orifice plate that is installed at horizontal pipe.

Differential pressure transmitter - 3-Valve Manifold for transmitter shall be used. - Transmitter body shall endure two times of maximum pressure. - In case of the following, diaphragm seal type or seal pot shall be applied.  Corrosive fluid or steam  Fluid that becomes solidified at low temperature  Fluid that becomes corrosive or solidified at stoppage  Fluid that blocks impulse lead pipe with solid in fluid  Fluid that becomes steam when the temperature of fluid rises up - When temperature or pressure changes severely, it needs to be compensated. - Changeable damping equipment shall be applied.

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Chapter 8 Instrumentation

③ Square root extractor

Square root extractor shall be applied. 3) Positive displacement ① The following specification of strainer shall be applied: Fluid

Mesh

Material of filter

Heavy oil

40

Stainless steel 304

Tar

60

Stainless steel 304

Light oil

40

Stainless steel 304

Water

40

Stainless steel 304

②

The material of rotor shall be selected according to the measured fluid. (In principle, Stainless steel 304) ③ Strainer shall be installed in parallel for oil and tar. ④ Accuracy of instrument shall be displayed. 4) Magnetic flow meter ① When detector and converter are installed separately, zero and span adjustment shall be possible at the side of converter. ② To prevent output signal change with fluctuation in fluid rate, damping circuits on which change over switch is attached shall be prepared. 5) Flow integrator Flow integrator shall have a low cut function. (3) Manometers 1) Pressure instruments ① Safety equipment shall be prepared to respond to excessive pressure. ② Impact absorbing equipment shall be prepared to respond to pulsation pressure. ③ When fluid becomes corrosive and solidified easily, the transmitter shall be protected with diaphragm or other equivalent one. 2) Bourdon type pressure gauge ① Type The types of applying pressure gauges shall be AS type or BS type according to the following diagram. Screw shall be 1/2 inch. ② Range of maximum measuring pressure 2, 6, 10, 15, 20, 50, 100, 250 kg/cm2

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Chapter 8 Instrumentation

③

Installation condition - Surrounding temperature shall be lower than 80℃. -

Syphon shall be applied at steam tube. Impact absorbing equipment shall be prepared to respond to pulsation pressure. When fluid becomes corrosive and solidified easily, seal type shall be applied.

-

BS Type

AS Type

Screw of 1/2 Pipe

Screw of 1/2 Pipe

④

Type

Bourdon type pressure gauge according to operation condition

When attaching to pipe

Condition Naming

Lower than 40℃

Higher than 40℃

Lower than 40℃

Higher than 40℃

AVS 1/2100

AHVS 1/2100

BVS 1/2100

BHVS 1/2100

High limit (Low limit) Alarm contactor

When attaching to wall

High limit InstrumentPanel

Vacuum contactor

(Low limit)

Vacuum contactor

AHVS 1/2150

BHVS 1/2150 Insulation and Vibration Proof Rubber

Plate(t=3.2)

2 more than 50kg/cm

: Non Hoop, Vibration Proof, 6 Angle

AHVS

: Non Hoop, Heat proof, Vibration Proof, 6 Angle

BVS

: Round Hoop, Vibration Proof,6 Angle

BHVS

: Round Hoop, Heat Proof, Vibration Proof



: Range of pressure

60

Note) AVS

100x50 Channel

Floor Anchor Bolt

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Chapter 8 Instrumentation

(4) Level instruments 1) Level measuring of fluid shall be selected according to the following

Fluid to be measured

table: Enclosed vessel

Opened vessel

Remarks

Pressure type

Heavy oil, tar

Differential pressure type

Bubble type, Ultrasonic type

Hydro-chloric acid, sulphuric acid

Displacer type

Differential pressure type

Benzol

Pressure type or Differential pressure type

Demineralized water

High viscosity or liquid that is solidified easily Corrosive liquid Oxidizable or explosive liquid Liquid that doesn’t allow impurities to penetrate Liquid that includes floating particles and dust

Bubble type, Ultrasonic type

Float type

Liquid that are easy to recrystalize

Bubble type, Ultrasonic type

Except the above

Ammonia water

Float type 2) Level meters of pressure type or differential pressure type (Sealed

type) ①

It shall be considered when installing this instrument that it can’t be checked or repaired unless the process is shut down and separated from. ② Water head of seal liquid that is filled in capillary can affect the measuring instrument’s adjustment. Therefore, installation location shall be checked before installation. ③ Error can occur by the change of surrounding temperature, so it shall be taken into consideration when applying it. 3) Float type level meter ① When there is a problem in operation, it is difficult to check the internal unit. So it shall be taken into consideration when installing it. ② In cases of slurry, fluid including solid, fluid of high viscosity, and fluid of easy coating, the float type shall not be applied. 4) Capacitance type level meter ① It is affected by the change of density of measured fluid. Therefore, it shall not be applied to such a fluid. ② When probe is coated, error can occur, so it shall be taken into consideration when applying it. 5) Displacer type level meter

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Chapter 8 Instrumentation

①

In case of the outside installation, caution is required since error occurs when temperature between vessel and level chamber are different. ② In case of the inside installation, internal equipment shall be supplied with stilling chamber. 6) Radioactive type level meter ① It is applied only when the other types cannot be applied. ② Obtaining permission from government and public offices shall be included in the supplier’s scope of supply. ③ If the material is built-up on the wall, error can occur. The supplier shall check the process completely. ④ When the density of measured material changes, error can occur. The supplier shall check the process completely. 7) Bubble type level meter It shall not be applied, if the characteristics of process fluid change according to purge gas. 8) Ultrasonic level meter ① Output signal shall maintain enough S/N ratio (Signal to noise ratio) considering the surrounding condition of measurement. ② Frequency of transmitters and receivers shall be designed considering noise frequency. Bandwidth of frequency shall be narrow for efficiency. ③ Automatic temperature compensation, echomiss compensating and damping control circuit shall be applied. ④ Zero and span adjustment shall be easily carried out. ⑤ If necessary, transmission probe shall be dust proof, water proof and heat proof. 9) Sounding level meter ① Wire and rod shall be designed considering mechanical strength, corrosion and high temperature. ② Correcting the measured value shall be easily carried out. ③ To protect transmitter from dust, drum shall be installed independently. Air purge shall be possible. 10) Microwave level meter ① It shall be able to measure raw material level in blast furnace, hot metal level in ladle and converter where dust can be produced much. It shall also be able to measure level of high temperature place. It shall not be affected by pressure. ② In high temperature area, cooling equipment shall be included in supplying items. ③ Lamp or buzzer shall be used to indicate that measured level exceeds highest or lowest value that is defined previously. ④ It shall have simple structure so that it doesn’t require mechanical maintenance.

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Chapter 8 Instrumentation

6.3.2

Control valve (1) The power source of the control valve shall be selected among electricelectric type, pneumatic- pneumatic type, electric- pneumatic type, and electric- hydraulic type. (2) When power source becomes out of order, control valve shall be opened, closed or locked considering the safety of process. If control valve is out of order while there is no bypass line, a handle shall be prepared to operate it manually. Even if the power is recovered, it shall not be operated by itself while in manual operation. (3) Calculation sheet for control valve sizing shall be provided. 1) Name of fluid 2) Type of control valve 3) Type of seat (Single, double) 4) Type of port 5) Flow characteristics (Liner, equal %) 6) Primary pressure 7) Minimum secondary pressure 8) Range of flow: Maximum and minimum 9) Quantity of leakage 10) Temperature of fluid 11) Saturated temperature 12) Saturated pressure 13) Flange type (4) Calculation sheet for control valve torque shall be provided and the (5) (6)

(7) (8)

reason of selected control valve shall be explained. If process connection is flange, the material of flange and its size shall be determined according to IEC, ISA and SNI or equivalent regulations. Stroke and torque of all control valves shall be decided considering the process condition. Especially, torque shall be more than 2 times of necessary value. Limit switch and torque switch shall be installed in control valve itself if necessary. Grease nipple, grease cap or lubricator shall be applied to valve shaft if

necessary. (9) Booster relay shall be applied to pneumatic type control valve, if necessary.

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Chapter 8 Instrumentation

(10) Materials of control valve shall be as follows:

Fluid

Water

Maximum primary pressure Less than 0.98 MPa or 10kg/cm2 More than 0.98 MPa or 10kg/cm2 Less than 147 KPa or 1.5 kg/cm2

Air

Steam

Connection diameter

Important parts

Remark

STS 304 SC Less than 100A

FC

STS 304

More than 150A(Butterfly valve)

SS, FC

Valve axis: STS 304

FC

STS 304

SC

STS 304

0.98~2.94 MPa 10~30 kg/cm2

Heavy oil, tar

Body FC

(0.16~0.98 MPa) 1.6~10 kg/cm2 Less than 0.98 MPa or 10kg/cm2

Less than 100A More than 150A(Butterfly valve)

Finex, mixed GAS

Material

Less than 0.98 MPa or 10kg/cm2 More than 0.98 MPa or 10kg/cm2

SC or SCA 51,52 SCS 13 SCS13

STS 304, STS 316 STS 304 Valve axis: STS 304

FC, SC STS 304 or STS 316 SC

O2

SCS 14

8-25

STS 304, STS 316

Satellite treatment

Chapter 8 Instrumentation

(11) If necessary, positioner, filter, regulating valve, oiler, solenoid valve,

speed regulator and equalizing valve shall be applied. (12) If limit switch and solenoid valve is installed at control valve, terminal

box shall be installed. Wiring from limit switches and solenoid valves to terminal boxes shall be pre-installed and supplied by the supplier. Solenoid valve shall be able to be manually operated at the field. (13) Rangeability of control valve shall satisfy the control range of process. (14) When the control valve is fully enclosed, leakage class shall be within the leakage class that is required at the process. ANSI B16.104-1976 shall be applied as a standard. Leakage shall not be allowed if it is required bubble tight. 6.3.3 Special instruments (1) General 1) Special instruments that are connected on-line to production and quality shall contain sufficient accuracy and efficiency necessary for each process and function accompanied automation 2) The supplier shall provide measuring system that corresponds with

surrounding conditions like temperature, moisture, steam, dust, mixed cooling water, moving pass line, and other factors. 3) Calibration shall be made automatically or manually both on on-line or offline. 4) Data sampling time rate, data collecting and responding time from measuring equipment shall be adequate for the job requirements. If necessary, the time rate shall be adjustable selectively. 5) The supplier shall provide basic program, source program and flow chart that are included in measuring equipment. 6) Each instrument shall be designed to perform self-test, diagnose trouble parts and adequately measure. (2) Protecting from radiation 1) The supplier who uses radiation facilities shall provide radiationprotecting facilities that are mostly adequate to the Indonesian law of atomic energy. Radiation leakage dose rate 1m apart from the surface of the source container shall be less than 7.5Sv/hr. 2) The supplier shall provide the following documents that are necessary to obtain the permission for radiation usage.

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Chapter 8 Instrumentation

①

3) 4) 5) 6)

Certificate of Radioisotope and source container and generator that are made by first manufacturer of the source. ② Mechanical drawings of source container.(Safety equipment) ③ Radiation leakage dose rate diagram radiated from source container ④ Description about protecting radiation After installing radiation equipment, field inspection report for radiation protection shall be submitted. Radio isotope and radiation generator shall be designed and installed considering anti-submersion, anti-loss and anti-fire. Source shall be able to be operated at installation place. Warning lamp shall be installed to indicate the open/close state of shutter. If the following radioisotope is supplied exceeding the regulated quantity, the supplier shall use B type transport container according to Indonesian law of atomic energy. The supplier shall provide proper data.

Intensity (Ci) Solid State

Other State

Specific Radioactivity

8 2 7 30

0.008 0.002 7 7

3.2 650 1,100 98

Radioisotope

Am241 CF252 Co60 Cs131

(3) Thickness gauge using radiation and X-ray generator 1) Radiation thickness gauge shall be able to measure thickness of all

the products. It shall compensate the change of temperature, density and pass angle of measured product. 2) At high-speed automatic gauge control line, X-ray thickness gauge shall be applied. 3) Frame of thickness gauge shall be made with stainless steel or steel in accordance with the condition. (4) On-line inspection equipment 1) When providing on-line inspection equipment, inspection theory and its experimental result shall be provided. 2) The actual and experimental data, such as special parameters, that shall be put in the system and must be included in the scope of supply.

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Chapter 8 Instrumentation

(5) Weigher 1) Weigher shall be supplied after inspection according to the the 2) 3) 4) 5) 6) 7)

Indonesian weighing law. Even if the weigher is modified, the above procedure shall be applied. When base frame is manufactured, error shall not occur according to bend of base frame that is caused by impact and concentrated load. Any error shall be within the limit of the weighing law. Providers of the inspection weight shall be determined after discussion between the supplier and KRI. Capacity of microcomputer shall have more than 30% of system availability. Load cell ① Measuring load Average weight + Repeatability (Regular weight of measured material) + Maximum vibration weight (Load cell capacity × Load cell quantity) shall be used. ② Allowable horizontal weight shall be more than 15% of the measured load. ③ The following shall be taken into consideration: - Temperature change - Surrounding vibration - Impact load - Influence of noise and external induced signals - Corrosion by moisture and salt ④ According to functions of the load cell, safe overload factors and maximum allowable load factors shall be determined.

8) Distance between load cell and load cell indicator (4-line cable)

shall be within 150m. Amplifier shall be used the distance 150m over. Cable shall be 4 lines or 6 lines of shielded, twisted and paired cable. 9) Slope of the base frame at an operation room shall be within 20°. 10) Measuring equipment shall not be affected by wind and rain. 11) Load cell shall be installed at dry place. If it is installed at a place where water can penetrate into the load cell, drain equipment shall be taken into consideration. 12) Test and inspection ① Standard and indication ② Function of machine and structural inspection ③ Inspection of material quality ④ Performance test ⑤ Unbalance check

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Chapter 8 Instrumentation

6.4 Panel instrumentation 6.4.1 Recorders and indicators (1) Recorder shall be a general pen type that doesn’t use special type of paper. The paper shall be fed by a motor. (2) Digital recorder that has a microprocessor shall be adopted. (3) The function of multipoint recorder shall be changed over by switch and quantity of point shall be selected among 4, 6, 12 and 24 points. (4) Plug-in method shall be port type considering exchangeability. (5) The range of a normal operation shall be less than 60% of the maximum range. (6) The speed of chart shall be changeable. (7) All indicators and recorders shall use the linear scale. (Logarithm scale shall not be used.) 6.4.2 Controller (1) Pneumatic type controller can be selected in case of process that requires explosion proof. It shall be compact and easily adjustable. (2) The set-up from upper level computer shall be possible. (3) Manual operation function shall be prepared for remote control. (4) Manual/automatic changeover shall be balanceless or bumpless. (5) Replacement of unit shall be quick and easy. (6) Direct or reverse action shall be applied considering safety of process when controller and transmitter are out of order. (7) In case of a batch process, an anti-reset wind up type shall be applied. (8) There shall be an output indication function of the controller. (9) Functions of alarm set, output limit, and set value limit shall be prepared. 6.4.3 Annunciator Operating sequence of an annunciator shall be manufactured and supplied based on the ISA Sequence Code 1B as follows: Annunciator condition

Process variable condition

Visual indicatior

Audible signal

Normal Alert Acknowledged Return to normal Test

Normal Abnormal Abnormal Normal Normal

Off Flashing On Off On

Off On Off Off Off

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Chapter 8 Instrumentation

6.5 Control system 6.5.1 Distributed Control System (1) General 1) Control system shall be a distributed control system to improve its reliability. The distributed control system means a system that can disperse the danger of control system according to the characteristics of process. 2) Central processing unit, communication processor and power supply module of control station shall be duplicated. 3) Distributed control system shall be able to communicate with process computer and other systems. 4) 30% of an entire memory capacity shall be kept free for expandability. 5) Linkage shall follow SNI and International standards-ISO, CCITT or IEC. 6) The following items shall be included in the estimate sheet: ① Type and speed of data linkage with upper level computers ②

Self-diagnostic and recovering method at each level ③ Changeover method and its necessary time when back-up system is composed ④ Type and speed of communication processor’s data transmission ⑤ Kinds of standard displays of manufacturer ⑥ Screen call-up time at standard display of manufacturer ⑦ Handling method in case of power failure ⑧ Data of system reliability In case of MTBF (Mean Time Between Failure), value of MIL 271 C shall be used as a calculation basis. ⑨ Loading and saving method of system program ⑩ Screen call-up time at user’s display ⑪ Process input/output list ⑫ System expandability (2) Hardware 1) System composition ①

Operator's station for monitoring and operation

②

Control station for process control ③ Logging printer for operation and alarm

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Chapter 8 Instrumentation

④

Hard copier ⑤ Logging printer (if necessary) ⑥ Communication equipment ⑦ Recorder and controller for back up (if necessary) 2) Operator's station ① Operator’s station shall have cathode ray tube(CRT) or TFTLCD monitor with key board. It shall also have function of monitoring and control of all process data. ② Operator’s station shall have equipment that can store data for a long time. ③ All the process data shall be automatically up-dated. ④ Operator’s station shall have function of back up. ⑤ Cathode ray tube monitor(CRT) or TFT-LCD will have one touch panel for quick operation by operator, if required. ⑥ Cathode ray tube monitor(CRT) or TFT-LCD will provide functions of Window and touch screen for human-machine interface, if required. 3) Control station ① Control station shall be panel type that has rack. It is composed of control equipment (central processing unit, memory module, communication processor, power supply module) and process input/output unit. ② Microprocessor shall be used at central processing unit. It shall have back-up function or duplicated action function. ③ Input/output module shall have spare input/output point in addition to net input/output points. It shall be more than 10% of entire quantity according to the each type of signal. ④ Input/output panel shall be designed considering minimum 10% of expandability of entire input/output point. 4) Communication processor and data way shall be duplicated structure. 5) When electric signal is used for interface, a relaying terminal box shall be applied. To interface on-off signal with electric equipment, a dry type contact shall be used. (3) Software 1) The main function of operator’s console is to monitor and operate process. In addition to operation function of standard display for monitoring and operation, display for process flow and all kinds of

8-31

Chapter 8 Instrumentation

data shall be available independently. 2) Problem oriented languages or fill in blank type shall be used for programming of sequence, monitoring, operation and control. 3) Input/output status and sequence shall be displayed at monitor(CRT) or TFT-LCD for maintenance. 4) When the hardware breaks down, the troubled part shall be displayed. 5) Ranges and constants shall be easily modified. 6) User’s display shall be called by one touch operation. Display

changeover time shall be within 1 second. 7) Specifications for interface with other systems, such as mechanical systems, electrical systems and other instrumentation systems, shall also be submitted. 6.5.2 Instrumentation panel Self-standing enclosed panel shall be applied. (1) Standard size of the panel shall be as follows: Main panel (mm) Width (W)

Height (H)

Thickness (T)

Depth (D)

Channel base

1,500 or1,800

100

600 Ceiling:

800 1,000 1,200

More than 3.2t 2,200

Wall: More than 1.6t

1,800 1) Doors shall be installed for maintenance. 2) Main panels shall be connected by bolt. Each panel shall be easily

added and separated. 3) Fluorescent lamp shall be installed for internal illumination of panel. Door switch shall be installed to turn the lamp on or off when door is opened or closed. 4) Anti condensation heater with thermal controller shall be installed at each row of panels. (2) Channel base

Channel base shall be composed as follows. If vibration dose not exist and insulation is not necessary, insulation & vibration proof rubber and plate shall not be installed.

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Chapter 8 Instrumentation

(3) Accessories 1) Power switch and fuse are individually installed in panel as a

electric power source for receivers (indicator, controllers, recorders, etc.), converters and transmitters. 2) 2 sets of AC 220V receptacle shall be installed in panel. Capacity and voltage of power shall be indicated. 3) Circuit for checking lamp and annunciator shall be installed. 4) Buzzer and lamp shall be operated when there occurs a failure. 5) Colors of the lamp shall be as follows: ① Primary input : Milk white ② Run : Green Red ③ Stop : Red Green ④ Alarm : Orange (warned by flicker) (4) Wiring 2 2 1) More than 0.6mm twisted wire (1.25 mm for the power) shall be used for the internal wiring of transmitter box and panel. If necessary, shielded wire and compensation wire shall be applied. 2) Colors of wiring shall be as follows: ① AC power and relay circuit - Non-grounded side: red - Grounded side: black ② DC power and relay circuit - Anode: Black - Cathode: White

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Chapter 8 Instrumentation

③

3) 4)

5) 6) 7) 8)

6.5.3

Control signal: Red, yellow, and blue ④ Grounding: Green - Yellow ⑤ Compensation wire - Black (R type) - Blue (K type) - Yellow (J type) Wire numbers shall be clearly printed and attached to the wire terminal and terminal block. If more than 2 instrumentation (controller, recorder, etc.) are connected serially, the circuit shall be automatically cut off for safety when each instrument is failed or wiring is cutoff. Power line and signal line shall be separated. More than 10% spare terminal shall be provided. Screw or plug type terminal shall be used. Transformer, terminal board and switch shall be applied.

Relay panel (1) Self-standing enclosed or wall mounting type panels shall be applied. (2) External terminal shall be installed. (3) Small capacity of relay shall be plug-in type. Tag No. shall be indicated at socket and relay. (4) When deciding the size of panel, space for maintenance shall be also considered. (5) Relay sequence diagram shall be attached in panel. (6) Transformers, resistors, and relays with large capacity shall be installed at the bottom of the panel. (7) Refer to the Paragraph 6.5.2 for other matters.

6.6 Utility for instrumentation 6.6.1

Sources of electricity (1) General 1) Powers for hydraulic and instrument air supply system shall be 220V, 1Φ, 50Hz or 380415V, 3Φ, 50Hz. 2) Capacity of power supply shall be more than 1.5 times of what is actually needed. 3) The supply of power shall be divided according to use and function. Line circuit breaker shall be installed individually at each line and usage of line shall be described. 4) On and off shall be displayed at changeover switch.

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Chapter 8 Instrumentation

5) Earth leakage breaker shall be applied for circuit maintenance. 6) Name plate that indicates load’s capacity shall be attached at each

breaker and switch. 7) By-pass line shall be installed at continuous voltage continuous frequency. 8) If necessary, transformers for instrumentation shall be installed independently. 9) Calculation sheet of power capacity shall be submitted. (2) Uninterruptible power supply Uninterruptible power supply of the following specification shall be provided. 1) General ① Cooling type : Enforced air cooling type ② Rating : 100% continuous ③ Controlling method : Silicon controlled rectifier control type ④ Noise : Lower than 60 dB ⑤ Operating method : Front panel direct operation ⑥ Monitoring method: Front panel monitoring 2) Electrical characteristics ① Output voltage regulation : Within ±2 % ② Output frequency regulation : Within ±5 2 % ③ Output voltage adjustment range : More than ±5 % ④ Load use range : 0 ~ 100 % ⑤ Output wave harmonic distortion :Within 5 % ⑥ Overload capacity : 10 minutes at 120% of rated load, 10 seconds at 150% of rated load ⑦ Transient voltage regulation : Within ±8 % (at 40% step load change) ⑧ Transient recovery : ±2 % : Within 50msec, ±1 % : within 100msec ⑨ Battery type : Ni-Cd pocket plate alkaline type, maintenancefree sealed type ⑩ Uninterruptible power supply time at power failure : 10-30 minutes (at full load) ⑪ Commercial power changeover time: Within 1/4 cycle (Unstopped changeover) ⑫ Rectifying method: More than 6 phases, 12 pulses full wave control method ⑬ Control method of rectifier and charger: Automatic constant voltage, constant current method.

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Chapter 8 Instrumentation

3) Detailed specification ① ②

③

④

⑤ ⑥

Function of walk in soft start shall be included to prevent malfunction or start-up failure because of transient phenomenon at start-up. Semiconductors for electric power shall be connected with high speed type quick cut-off fuse so that damage of one device shall not affect the other devices. Lamp and buzzer that are attached to panel shall be operated when power fuse is melt down. To prevent ripple current from flowing through battery, output filter shall be installed. And the ripple current shall not exceed 3% of RMS value. If DC voltage reaches the highest over voltage that is defined, input power of rectifier and charger shall be automatically cut off; and the load shall be uninterruptible changed over to bypass circuit by DC over voltage protection circuit. AC input circuit breakers shall be an automatic cut off insufficiency voltage trip type when there is no control voltage. Rectifier transformer shall be high efficient mold transformer.

⑦

Control equipment of inverters shall make it possible to compensate phase voltage up to maximum 3060% unbalanced load for phase balance. ⑧ Filter that reduces harmonic that comes back from load shall be applied in. ⑨ Surge absorber or surge snubber shall be applied to absorb surge caused by abnormal input voltage and current. ⑩ Battery panel shall be maintenance-free and enclosed type poisonous gas that may come from battery, and surrounding panels shall not be corrupted. ⑪ Protective and warning parts shall be existed for main parts. ⑫ When uninterruptible power supply is out of order, it shall switch over to commercial power and process operation shall not be affected by the disorder of UPS. (3) Power distribution panel 1) All cables that are connected to panel shall be come in through the bottom of panel. 2) If necessary, adequate circuit breaker shall be applied. 3) Voltmeters and ammeters shall be installed.

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Chapter 8 Instrumentation

4) Single line diagram shall be attached on inside panel.

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Chapter 8 Instrumentation

6.6.2

Sources of instrument air (1) Oilless type air compressor shall be selected for instrument air source for instrumentation. The capacity shall be 2 times of what is actually needed. (2) Composition of instrument air source for instrumentation shall be as follows. It shall automatically switched with one another.

Air tank

Compressor After cooler Compressor

Check valve

Cooling water

Drain separator

Check valve Plant Air on-off valve

Reducing press valve

F

Filter

F Air Dryer

F

Instruments Insruments

(3) Instrument air supply line shall be separated according to each use and

function. 1) Instrument 2) Actuator 3) Cooling line 4) Purge 5) Others 6) Spare (4) Calculation sheet for air compressor and tank shall be provided. (5) Air dryer shall be adsorption type or refrigerator type (6) Air supply equipment shall be designed considering pressure drop.

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Chapter 8 Instrumentation

(7) Output air condition of air control equipment shall be as follows: 1) Pressure : 7 ±0.5kg/㎠ (0.68±0.05 MPa) 2) Temperature : Indoor temperature 3) Dew point : Lower than -10℃ 4) No dust, oil, or corrosive gas shall be included. (8) The capacity of air receiver tank shall be larger than what is consumed

during 10 minutes. 6.6.3 Hydraulic source (1) Hydraulic supply system shall endure reverse flowing pressure when power failure occurs. (2) Stop valve shall be installed at inlet/outlet parts of oil tank, each distribution line and ending parts. If necessary, accumulator shall be applied. (3) Calculation sheet for capacity of hydraulic source and accumulator shall be provided. (4) Stand-by pump shall be installed with automatic changeover device. (5) Operation lamp shall be installed at central control room and local panel. (6) Pressure gauge and corrosion protecting filter shall be installed at outlet of oil pressure pump. (7) Level instrument, temperature instrument, maintenance hole and drain hole shall be installed inside oil tank. If necessary, oil cooler and oil heater shall be included. (8) Oil shall be selected according to operation condition and be confirmed by KRI. (9) Low carbon steel pipe shall be applied as oil distribution tube. (10) Gasket type shall be applied at connection part of hydraulic system. (11) "H" type of insulation shall be applied to solenoid valve coil. Spark killer shall be applied at DC coil. (12) Diameter of ventilation pipe of oil tank shall be larger than 32mm and be located at top. (13) Copper filter of 40 Mesh shall be installed to protect back fire. 6.7 Others 6.7.1

Control room & panel room (1) Route for entrance and transportation of instrumentation equipment shall be considered. (2) Enough space shall be made considering operation, maintenance and future expandability. (3) Maintenance space for each instrumentation equipment shall be prepared.

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Chapter 8 Instrumentation

(4) Distance between wall and instrumentation equipment shall be more than

1.5m. (5) The floor shall be designed considering enough strength for heavy

instrumentation equipment and enough insulation for instrumentation equipment. (6) When designing, the following shall be taken into consideration. 1) Low noise 2) Low vibration 3) Protecting dust, corrosive gas and water 4) Minimum heat transfer from process facilities (7) Emergency lighting system shall be designed and it shall be sufficient

intensity of illumination. (8) Adequate smoke detector and fire alarming equipment shall be installed. Fire extinguishers shall be installed at necessary place. (9) Fire fighting plan shall be set up at cable entrance hole. 6.7.2 Grounding Standard grounding resistance of instrumentation equipment shall be as follows. And the other details shall follow 7.3, Part 7, ISZ-2. -

Signal Ground: Special 3 class grounding (10 Ohm) Frame Ground: 3 class grounding (100 Ohm)

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Chapter 8 Instrumentation

7.0 Test and inspection standards 7.1 Shipping test and commissioning 7.1.1 Procedure for shipping test and commissioning shall be provided and approved by KRI. 7.1.2 KRI has a right to participate in Shipping test and commissioning. 7.1.3

Shipping test The supplier shall perform shipping test according to procedure approved by KRI. The supplier shall then provide the result of test including input/output data.

7.1.4

Commissioning Commissioning of instrumentation equipment shall be as follows. (1) Adjustment of each instrumental equipment. (2) Fine tuning of each loop including PID (Proportional Integral Derivative) variables. Control system shall include simulation test of hardware, off-line adjustment and detail adjustment, on-line adjustment and fine-tuning.

7.1.5 The supply of special equipment and material that are needed for test and commissioning shall be determined after discussion between the supplier and KRI. 7.1.6

The result of commissioning shall be provided to KRI without delay.

7.2 Preliminary acceptance test 7.2.1 The supplier shall provide PAT check sheet and be approved by KRIIndonesia before performing PAT. 7.2.2

The supplier shall perform PAT of instrumentation equipment at no load state. After the test the supplier shall provide the test result to KRI according to contract specification. KRI shall issue preliminary acceptance certificate if the result of PAT is satisfied.

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Chapter 8 Instrumentation

7.3 Final acceptance test After PAT, FAT of instrumentation equipment shall be performed. Issuing condition of Final Acceptance Certificate shall be as follows. Hardware shall satisfy more than 99.7% of availability at 720 hours continuous operation. Hardware and software shall satisfy the performance described on contract specification. 7.4 Warranty 7.4.1

Warranty period shall be 1 year after FAT has been passed. Warranty period shall be discussed with KRI according to the characteristics of facilities. If trouble happens during this period, the supplier shall provide service and repair for its own expense when there is no fault of KRI- Indonesia. --- > shall be clarified later refer to the final contact clausal.

7.4.2 Actual warranty method shall be included in estimate sheet. 7.4.3

The condition of warranty shall be written in each specification.

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Chapter 9 Process Computer

Chapter 9 Process Computer

9-1

Chapter 9 Process Computer

Table of Contents 1.0

General ......................................................................................................................

3

2.0

Design conditions ..................................................................................................

7

3.0

Engineering services and supervision ...............................................................

8

4.0

Painting and coloring standards .........................................................................

8

5.0

Packing standards ....................................................................................................

9

6.0

Design criteria ........................................................................................................

9

7.0

6.1

General ...............................................................................................................

9

6.2

Hardware system ..............................................................................................

10

6.3

Software system ...............................................................................................

14

6.4

Network system ................................................................................................

14

Test and inspection standards ...............................................................................

15

9-2

Chapter 9 Process Computer

1.0

General 1.1 Scope of application This standard is applicable to general technical specifications used to purchase all process computer systems supplied to KRI- Indonesia. 1.2 Scope of supply 1.2.1

Definition of terms (1) Technical data Design data used to carry out basic engineering works based on the basic plan, including the following: 1) Plant layout 2) Control room and computer room layout plan 3) Process flow diagram 4) Operator working manual 5) Other results from site survey (2) Basic design Design works forming the basis of final system specification preparations, detail design, and application software development, including the following items: 1) Hardware system configuration and specifications 2) Software system configuration and specifications 3) General functional correlation diagram (3) Detail design This is the process computer system’s detail design prepared based on the above basic design, and includes the following functions: 1) Interface to other systems ① Interface to business computers ② Interface to Level ③ Interface to other computers 2) Operator guidance 3) Data logging 4) Application model 5) Setting control 6) Others

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Chapter 9 Process Computer

1.2.2

Scope of supply (1) Process computer system 1) Hardware system 2) Software system ① Basic software (All software except application software shall be included herein.) ② Application software (To be decided based on mutual discussion.) 3) Network system 4) Consumable items 5) Maintenance tool 6) Others (2) Design and engineering The supplier shall perform the following works necessary for the construction, operation, and maintenance. 1) Design for equipment installation at site. 2) Design for construction of process computer system 3) Submission of drawings and documents 4) Design and development of application software (3) Supervision related to installation work at site The supplier shall perform supervisory services in relation to the installing of equipment at site. 1) Technical explanation and advice related to installation works 2) Provision of guidance and advice with respect to transporting and unloading 3) Provision of guidance and advice relating to commissioning (4) Commissioning and adjustment After the completion of installation work, the supplier shall submit a commissioning manual to KRI. The supervisor shall attend the commissioning (PAT and FAT) to provide guidance and advice. (5) Inspection, packing, and transporting of equipment Inspection and packing of the equipment shall be carried out according to the provisions of Paragraph 5.0 and 7.0, and the equipment shall be transported to places designated by KRI. (6) Training The supplier shall submit a training schedule covering the equipment operation and maintenance together with the contract specifications. The supplier shall conduct training according to the training schedule; however, the number of students and the training period shall be decided based on discussion between KRI and the supplier.

9-4

Chapter 9 Process Computer

(7) The supplier shall present lists of special cables that cannot be procured

within the domestic, and procurement program shall be decided based on mutual discussion. 1.2.3 Items out of the scope of supply: All construction works enumerated below, except those performed directly by the technicians of the supplier, shall be carried out by KRI. (1) Foundation and installation work of the process computer system (2) Engineering works and materials related to the existing plant systems up to the primary point of receiving switch gear to supply of power and control of supplied equipment. (3) Installation works related to the supply of utilities required to carry out main equipment installation work (4) Telephone and premises communication systems (5) Procurement, tools, materials, and temporary construction materials required for field installation and installation work. (6) Material for, and construction of, indoor and outdoor lighting systems, cooling and heating systems, indoor and outdoor hydrants, water supply, and drainage systems (7) Unloading and storing of the delivered equipment (8) Procurement of equipment and materials generally required for tests and operations 1.2.4

Other matters requiring classification of supply shall be decided based on discussion between KRI and the supplier.

1.3 Drawings and documents The supplier shall submit the following drawings and documents to KRI- Indonesia according to the schedule agreed with KRI. 1.3.1 Documents to be included in the estimation (1) Experience of the supplier relating to the process computers, including the following items, shall be described in details in the estimation specifications. 1) Name and location of plant 2) Detailed description about how the computer functions have been used successfully based on the past experience (2) Details of equipment (3) Brief description of computer system functions (4) Hardware configuration and specifications (5) Software configuration (6) Brief description of process operation procedures at plant (7) Main computer input/output(I/O) signals and number of points by types of I/O (8) Environment required for the installation of computers

9-5

Chapter 9 Process Computer

(9) (10) (11) (12) (13) (14) (15)

List of testing equipment List of descriptive documents relating to the contents List of consumable items and spare parts System fabrication and installation schedule Warranty method Brief description of application models Catalogues

1.3.2 Documents to be submitted prior to signing contract All items contained in the estimation shall be supplemented, with specifications described in more details. 1.3.3

Documents to be submitted after completing detail design of hardware system: (Instruction manuals shall be finalized at this time.) (1) Supplemented hardware specifications and configuration (2) Control room/Panel layout (Computer room included) (3) Supplemented input/output signal list (4) Cable list (5) Description of functions about set up/display devices (6) Data link method to other computers (7) Detailed description of process operation procedures relating to the equipment (8) Explanation related to tracking logic (9) System console and logging typewriter’s printing item and time (10) Installation work drawings

1.3.4

Documents to be submitted after completing detail design of software system: (1) Memory map (Main/Auxiliary) or database design documents (2) Basic and application software specifications (3) Program configuration(Basic and application software) (4) Application task level allocation (5) Tasks/subtask function allocation (6) Process input/output allocation (7) Device address allocation (8) Alarm message specifications (9) Detailed application model description

9-6

Chapter 9 Process Computer

1.3.5

Documents to be submitted when systems are shipped (1) Maintenance & operation manual (2) Standard software documents 1) Basic software - Description on function and operation 2) Application software - The supply scope shall be decided according to the provisions of Paragraph 1.2.2. (3) Programming hand book (4) Test manual and program (5) installation work specifications (6) Factory test reports (7) Process schedule (8) Instruction manual (9) Final version containing all corrections and supplementations made to all items described under Paragraph 1.3.3 and 1.3.4. (10) Troubleshooting guide (11) Operation manuals

1.3.6

Documents submitted prior to the completion of F.A.T shall contain items specified in Paragraph 1.3.5 which have been changed or revised during commissioning.

1.3.7

Final documents shall be submitted in appropriate media(i.e. paper, compact disk and computer File). If the documents are to be submitted in the form of compact disk or computer files, such documents shall be prepared in English using the word processor designated by KRIIndonesia.

2.0 Design conditions 2.1 General Design conditions shall be governed by the provisions of KRI’s purchase specifications and Part 4 Design conditions, ISZ-1. 2.2 Design conditions and standards These conditions are applicable to the process computer system design, manufacture, test and inspection based on the provisions of this Chapter, KRI construction and inspection standards. Items not applicable to these standards shall be governed by the following standards:

9-7

Chapter 9 Process Computer

2.2.1

KS(Korean Industrial Standard)

2.2.2

ISO(International Organization for Standardization)

2.2.3

JIS(Japan Industrial Standard)

2.2.4

JEM(The Standard of Japan Electrical Manufacturer Association)

2.2.5 SNI(Indonesian Standard) 2.2.6 DIN 2.2.7

IEC

2.2.8

IEEE

2.2.9

ISA

2.2.10 Maker's Standard 3.0 Engineering services and supervision 3.1 Engineering services The supplier shall perform the following engineering works for construction works and operation of equipment. - Design for equipment installation at site - Design for construction of the process computer system - Submission of drawings and documents - Application software design and development 3.2 Supervision The supplier shall perform the following supervision services: 3.2.1 Supervision services for site installation (1) Technical explanations and advice related to installation works (2) Provision of guidance and advice with respect to transporting and unloading (3) Provision of guidance and advice relating to commissioning 4.0 Painting and coloring standards 4.1 General

9-8

Chapter 9 Process Computer

9-9

Chapter 9 Process Computer

4.1.1

The supplier shall select paints and painting procedures suitable to the environmental conditions and operating conditions of KRI equipment.

4.1.2

The supplier shall obtain approval of KRI for the selected paints, color and, painting procedures.

4.1.3

All equipment shall be painted by the supplier.

4.2 Computer color standards Supplier’s standard colors shall be used for such standard products as the Central Processing Unit(CPU) and peripheral equipment; however, colors of the panels installed on the operation desk or in the control room shall following the color regulations pertaining to electrical systems and instrumentation. (Indoor type : 7.5 BG 6/15) 5.0 Packing standards Process computer systems shall be properly packed to protect the systems from external moisture and/or impact and damage that might be caused during transporting; and shall not cause performance deterioration, which might be caused by corrosion, even when the systems are stored for a long period of time at site. 6.0 Design criteria 6.1 General 6.1.1

These standards are applicable to the process computer system design.

6.1.2

If there are differences between the supplier’s specifications and the specifications described hereunder, the supplier shall present reasons therefore and improved substitute specifications to obtain official approval from KRI.

6.1.3

Definition of terms Process computer system used herein carries composite meaning covering the CPU, peripheral equipment, software, network, and other devices required for process control.

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Chapter 9 Process Computer

6.1.4

The process computer system software and hardware shall be designed and manufactured after considering the system reliability, efficiency, maintainability, and extensibility. 6.1.5 Approval (1) System design documents shall be subject to KRI’s prior approval. System description shall be included within the system design. (2) Even if all documents and drawings are approved by KRI, the supplier is responsible to provide the best systems in order to realize the contracted functions. 6.1.6

The system shall specify international standards covering each system in the estimation.

6.2 Hardware system 6.2.1

All system devices shall be designed and manufactured to suit power supply with frequency of 50Hz, and line voltage measuring 220V or 220/110 380, 3phase/220, 1phase V.

6.2.2 All systems shall be dustproof and gas-resistant. All equipment installed in the control room or on the operation desk at site shall be waterproof. Minor errors of the peripheral equipment shall not cause trouble to overall system. 6.2.3

Appropriate measure shall be taken against the vibration of the computer systems, including measures against noise created by the static induction and electromagnetic induction.

6.2.4

Computer systems which have acquired EMC (Electromagnetic Compatibility) based on the *1EMI(Electromagnetic Interference) prevention standards and the *2 EMS(Electromagnetic Susceptibility) standards shall be used.

6.2.5

Appropriate devices shall be adopted to improve system reliability.

6.2.6

CPU (1) The process computer system’s CPU shall be designed in such a way that if one CPU fails, the back-up CPU will automatically take over the job of the troubled CPU. However, the back-up CPU configuration shall be decided based on discussion between KRI and the supplier in according to a place of application. (2) The estimated load rate of the CPU, during normal operation, shall not exceed 40%.

*1

EMI(Electromagnetic Interference) Prevention Standards (Ministry of Information and Communication, A notice No. 1997-41). *2 EMS(Electromagnetic Susceptibility) Standards (Ministry of Information and Communication, A notice No. 1997-42).

9-11

Chapter 9 Process Computer

(3) The following devices or functions shall be included: 1) Memory protection 2) Interface for I/O control 3) Floating point processor 4) RASIS(Reliability, Availability, Serviceability, Integrity, and Security) 5) Watch dog timer 6) ECC(Error Correction Code) 7) Automatic re-starting after power supply returns 8) Self-diagnosis 9) Real time block with battery backup function (4) Any abnormal temperature or humidity of CPU shall be detected and an

alarm shall be issued to the operator. 6.2.7 Main memory The main memory capacity shall be proposed with due regards to the CPU cycle time, operation speed, system function, and extensibility. 6.2.8 Hard disk systems (1) Hard disk systems shall be designed to store all CPU Data, and facilitate initialization of the CPU system. (2) Memory protection function shall be provided. 6.2.9 Logging printer (1) Interface of the logging printer to other equipment shall be governed by the provisions of any of international standards (i.e. EIA, CCITT, IEC or ISO). (2) An on-line bank-up system shall be presented in consideration of the entire quantity and characteristics of the logging printer. (3) Self-diagnostic function shall be provided. (4) Indonesian output shall be included. 6.2.10 System printer (1) Printer type shall be a laser printer. (2) In the case of a multi-CPU system, the laser printer must be able to be used by numbers of CPUs. (3) The paper width and the number of lines per inch shall be able to be adjusted.

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Chapter 9 Process Computer

(4) The system printer shall carry a bit image mode which enables English

output function. (5) Self-diagnostic function shall be provided. 6.2.11 Human-Machine Interface(HMI) (1) For HMI, a common VDU and keyboard featuring the window, Graphic User Interface(GUI), track ball or touch screen function shall be provided. (2) If the VDU and keyboard are insufficient to allow communication between human and machines, a separate optimal device shall be provided in addition to the VDU and keyboard. Installing this device within the control room shall be subject to prior approval. (3) The screen size and the transmission speed shall be decided according to the function of the system. (4) Keyboard shall be dustproof and waterproof. (5) Specifications of the HMI software and hardware shall be included in the estimation. The estimation shall be inscribed international standards related to HMI. 6.2.12

Digital Audio Tape (DAT) systems Digital Audio Tape systems that can be interfaced with the CPU shall be chosen.

6.2.13 Compact Disk (CD) Compact disks that can be interfaced with the CPU shall be chosen. 6.2.14 Uninterruptible Power Supplies (UPS) (1) General 1) For certain equipment which require uninterruptable power supply of constant voltage and frequency, UPS shall be used. 2) This standard shall be applied based on IEEE 944, the IEEE Recommended Practice for the application and testing of UPS. 3) The I/O rated voltage shall be governed by the provisions of the maker’s standards or KRI’s requirements. 4) Rated capacity shall be decided according to the status of 100% continuous load. 5) Overload capacity shall be governed by the provisions of maker’s standards or KRI’s requirements 6) Circuit system : Static converter-inverter system 7) UPS cooling system shall be forced air-cooled type. 8) The UPS shall carry automatic static by-pass switch. 9) The power distribution panel shall carry surplus feeders of at least 20% of the total number of feeders equipped with circuit breakers. (2) System requirements 1) Panel type shall be an indoor, stand-alone type.

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Chapter 9 Process Computer

2) Circuit ① The controller shall be of a static converter-inverter type

capable of displaying the constant voltage and requirements. ② The condition of the UPS shall be displayed on the HMI or the operation desk installed in the maintenance or control room. ③ The controller shall be composed of a protective part and a controller part. ④ Controller circuit shall be electrically isolated from the power supply part. 3) Electric characteristics ① In the case of synchronous changeover resulting from the system failure, power restoration or outage under the nonlinear load status ranging from 0 to 100% of the control system such as the computers or PLC, the output voltage variation shall be within ±20% of the rated output voltage. ② the output voltage variation under the 0∼100% normal load shall be ±1% of the rated output voltage. ③ Overall harmonics distortion under the 0∼100% nonlinear load of the control system, such as the computer or PLC shall be less than 5%. ④ In case of power failure, the battery back-up time shall be at least 30 minutes or as required by KRI. All operating units shall carry good workability and maintainability. As for fuses, high-speed type shall be used to protect the semiconductor device from damage. ⑤ The power distribution panel shall be installed in the computer room. ⑥ Feeder and equipment shall be designed at a 1:1 ratio. 4) Maintenance ① All operating units shall carry good workability and maintainability. As for fuses, high-speed type shall be used to protect the semiconductor device from damage. ② Battery shall carry uniform charging function, and shall be selected based on the maker’s standards or KRI’s requirements. ③ Appropriate information shall be displayed in the display unit in case of power outage or other failure. ④ Voltmeters, ammeters and frequency meters shall be installed on the front of panel. The meter grade shall be 1.5 or higher.

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Chapter 9 Process Computer

6.2.15 Consumable items (1) Consumable items shall be supplied under the following conditions: The period of supply shall start from the date of PAC issuance. 1) Supplier’s special items : 1 year --- > shall be clarified later 2) Others (2) The supplier shall present the quantity of consumable items in consideration of the system reliability. 6.2.16 The supplier shall guarantee availability of the spare parts or equivalent items during 10 years after the system is installed, and the price of each spare parts shall be submitted prior to signing contract. 6.2.17

Maintenance tool Tools available only at the supplier shall be supplied along with the computers.

6.3 Software system 6.3.1 Software system configuration is as follows: (1) Operating system (2) Language (3) Utilities (4) Other items The system shall be able to be created and operated at site. 6.3.2 Application software (1) The supplier shall provide application software satisfying the requirement of process based on experience and know-how. (2) The HMI display response time shall be designed as short as possible, but shall not exceed 2 seconds. (3) Simulation function shall also be provided for off-line test. 6.3.3

The basic software usage and the application software list shall be submitted to KRI.

6.4 Network system 6.4.1

The process computer system shall be configured in the on-line network to the business computers, other process computers or Human-Machine Interface(HMI) systems.

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Chapter 9 Process Computer

6.4.2

The communication system shall observe international standards(ISO, CCITT or IEC).

6.4.3

The network system shall be embodied in an open architecture system taking into consideration of future extensibility, compatibility, and the standard network profile. The detailed specification shall be decided based on discussion between KRI and the supplier.

6.4.4

As for the network system configuration, a duplex network system equipped with 2 units of backbone networks featuring common network is recommended. In general, one side shall be used as an on-line system. However, in case the network system downs, the system shall be substituted by the backbone network under the hot standby so that on-line networking can be operated continuously. For a small scale system or an auxiliary system, single network system may be configured.

7.0 Test and inspection standards 7.1 Factory test and commissioning 7.1.1

Sufficient prior discussion shall be held with respect to the shipping test and commissioning procedures to obtain KRI approval.

7.1.2

KRI has right to attend factory test and attend commissioning.

7.1.3

The supplier shall submit shipping test items and procedures prior to conducting the shipping test. For the software test, detailed simulation procedures and the I/O data shall also be submitted.

7.1.4

Computer systems shall be shipped after successfully completing the factory test.

7.1.5

The factory tests are classified into a hardware assembling test, a software and hardware functional test, and an overall operation test.

7.1.6

The instruments and equipment, and consumable items required for the system test and adjustment shall be provided by the supplier.

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Chapter 9 Process Computer

7.2 PAT The process computer’s PAT shall be consisted of the following: 7.2.1 H/W reassembling test 7.2.2 System generation and program restoration 7.2.3 Off-line trial operation 7.2.4 Software simulation 7.3 FAT The process computer’s FAT shall be consisted of the following: 7.3.1

On-line trial operation

7.3.2

System fine adjustment

7.3.3 When the software and hardware system achieves 99.7% or better of operation ratio in continuous operation for 720 hours after completing the commissioning, and the software demonstrates performance required by contract, the take over the computer system shall be realized. The hardware as used herein means the CPU, hard disk systems, and/or other devices which might cause system failure. 7.3.4 FAT shall be conducted after successfully completing commissioning. FAT shall not be conducted if the function as required by the contract has not been confirmed both parties to the satisfaction. 7.3.5 If a failure occurs or an IPL(Initial Program Loading) begins due to unknown causes even after the system is restarted 3 times, the continuous operation time integration shall be reset and reconfirm to KRI.

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Chapter 9 Process Computer

7.4 Inspection 7.4.1 Incoming inspection An inspection shall be conducted for the incoming process computer systems to determine if all requirements have been satisfied. 7.4.2

Inspection during the process of installation and commissioning Inspections to be conducted during the process of installation and commissioning shall be carried out for each stage of work.

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Chapter 10 Communication

Chapter 10 Communication

10-1

Chapter 10 Communication

Table of Contents 1.0

General .....................................................................................................................

3

2.0

Design conditions ..................................................................................................

6

3.0

Engineering .............................................................................................................

6

4.0

Painting and coloring standards ............................................................................

6

5.0

Packing standards ....................................................................................................

7

6.0

Design criteria .........................................................................................................

8

6.1

General criteria ................................................................................................

8

6.1.1 I-TV system .............................................................................................

8

6.1.2 Paging system .........................................................................................

10

Standard basis ..................................................................................................

13

6.2.1 I-TV system .............................................................................................

13

6.2.2 Paging system .........................................................................................

23

Test and inspection standards ...............................................................................

25

6.2

7.0

10-2

Chapter 10 Communication

1.0 General 1.1 Scope of application It shall be applied to the I-TV and Paging systems that are supplied to KRIIndonesia. 1.2 Scope of supply 1.2.1 Range of supply (1) Communication systems (2) Design and Engineering The supplier shall perform the following works required for construction, operation and maintenance. 1) Design for the installation of the equipment at site. 2) Submission of the list of tools and materials with general specifications to be provided by KRI. 3) Submission of drawings and documents (3) Supervision of installation work at site. The supplier shall provide supervisory service for installation at site. 1) Technical description and advice related to installation works. 2) Guidance and advice with respect to transporting and unloading. (4) Commissioning and adjustment Upon completion of installation, the supplier shall submit a commissioning manual to KRI. Supervisor shall attend the commissioning (Preliminary acceptance test, and final acceptance test) to provide guidance and advice. (5) Inspection, packing and transporting of equipment Inspection and packing of the equipment shall be carried out according to the provisions of Paragraph 7.0 Test and Inspection Standards, and Part 5 Painting, Coloring, Packing, ISZ-1. The equipment shall be transported to places designated by KRI. (6) The supplier shall submit the list of special cable that cannot be procured in Indonesia, and procurement plan shall be decided based on mutual discussion. (7) The supplier shall submit manuals, drawings and other related data related to construction, commissioning, operation and maintenance. 1.2.2 Items out of the range of supply All construction works enumerated below, except those performed directly by the technicians of the supplier shall be carried out by KRI.

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Chapter 10 Communication

(1) Foundation and installation work for communication equipment (2) Installation works related to supply the utilities required for main (3) (4)

(5) (6) (7)

equipment Procurement of equipment, tools, materials, and temporary construction materials required for field installation, and installation work. Materials for, and construction of, the indoor and out door lighting apparatus, cooling and heating apparatus, indoor and outdoor hydrants, water supply and general drainage. Unloading and storing of the delivered products. Procurement of the equipment and materials generally required for test and operation. Preparing personnel who will perform the commissioning

1.2.3 Other matters related to the scope of supply shall be decided based on mutual agreement. --- > shall be defined at the contract 1.3 Drawings and documents The supplier shall submit drawings and documents as specified in Part 2 Estimation, ISZ-1 according to schedule agreed upon between the supplier and KRI- Indonesia. The following items, in particular, shall be added to those drawings and documents. 1.3.1 When submitting an estimation (1) Specifications of equipment (2) Price list of equipment (3) Scope of supply table (Supplier and KRI) (4) Project and work schedule (5) System description (6) Panel drawings (if needed) (7) Operation desk drawings (if needed) (8) Utility drawings (power supply, and instrument air, etc.) (9) Interface specifications of system inside and specifications for interface with other systems. (Data Linking method) (10) Surrounding conditions for installation (11) Equipment required for commissioning (12) Training plan (13) Each equipment catalogue (14) Other required data 1.3.2

When contracting The same list required for estimation above shall apply. If any change is required, decision shall be made based on mutual agreement between KRI and the Supplier.

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Chapter 10 Communication

1.3.3

At the time of preparing basic design (1) Single Line Diagram (2) Block diagram of communication system (3) Configuration diagram of communication system

1.3.4 At the time of preparing detail design (1) Communication system design 1) Detailed descriptions of the system 2) Sheets of measuring calculation for system component 3) Noise distribution chart in the place of installation 4) Calculation data of the utility requirements 5) Interface specifications of system inside and specifications for interface with other systems. (Data Linking method) 6) Detailed wiring diagram of replaceable module 7) Fabrication specifications 8) Other required data (2) Construction design 1) Arrangement plan of communication equipment 2) Cable Route Plan 3) Control Room & Panel Room Arrangement 4) Installation Details 5) Cable Schedule 6) Interconnection Diagram 7) Detailed description regarding installation work 8) Other required data 1.3.5

At the time of shipment (1) Shipping documents (2) Pre-shipment test reports

1.3.6 At the time of adjustment (1) Adjustment Manual (including trouble shooting) (2) Results of adjustment 1.3.7 At the time of PAT/FAT (1) Test Manual (2) Test report

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Chapter 10 Communication

(3) Final drawings and documents

Final drawings and documents shall contain information on items corrected during the process of installation and commissioning. The list and quantity of drawings and documents to be submitted shall be made based on Part 2 Estimation, ISZ-1. 1.3.8

For maintenance and operation (1) Operation Manual (2) Maintenance Manual

1.3.9 Others All drawings and documents shall be prepared in good-quality paper, and shall be prepared according to Part 2, Estimation, ISZ-1. 2.0 Design conditions 2.1 General Design conditions shall follow the purchase specifications and Part 4 Design conditions, ISZ-1. 2.2 Design standards These standards are applicable to the communication equipment and communication interface system design, manufacture, test and inspection based on the provisions of Chapter 10 Communications, ISZ-2, and KRI construction and inspection standards. Items not applicable to these standards shall be governed by the following standards: 2.2.1 IEC 2.2.2 IEEE 2.2.3 ISO (International Organization for Standardization) 2.2.4 Indonesian Standards 2.2.5 KS (Korean Industrial Standard) 2.2.6 ANSI (American National Standards Institute) 2.2.7 DIN (Deutsche Normen) 2.2.8 JEM (The Standard of Japan Electrical Manufacturer Association) 2.2.9 JIS (Japan Industrial Standard) 2.2.10 Maker’s Standards 3.0 Engineering Provisions of Part 3 Engineering, ISZ-1 shall be applied. 4.0 Painting and coloring standards The painting and coloring of communication equipment shall follow Part 5. Painting · coloring packing, ISZ-1.

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5.0 Packing standards Communication equipment shall be properly packed to protect from external moisture and/or impact and damage that might be caused during transportation, and shall not cause performance deterioration or corrosion even when the systems are stored for a long period of time at site. For other detailed matters shall follow Part 5. Painting coloring · packing ISZ-1.

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Chapter 10 Communication

6.0 Design criteria 6.1General criteria : 6.1.1

I-TV System - The observation system of operation facility - The observation system for fire and manned/unmanned facility.

6.1.2 Standard model (wire /wireless system) - Analog system that is not necessary connected with LAN shall be display in the monitor, directly. - Analog system connected with LAN shall converted digital IP. - Area without LAN shall be transmitted through the wireless LAN. - Transmission method of Wireless AP shall be selected among a, b and g in accordance with condition (Frequency :a(5.8GHz), b/g(2.4 GHz)). (1) Camera 1) The image pick-up element shall be a high-sensitive solid-state component which uses a semiconductor integrated circuit. 2) The image pick-up element size and the image pick-up range are as follows: ① Standard of lens application ■ Image Size(mm) 1" 2/3"

9.6

16

6.6

12.8 X (image

■ X 촬상 ( 범위) = pick-up range)

1/2"

4.8

11 8.8

1/3"

8 6.4

3.3 4.4

Distance lens and거리 objectx×Image size 렌즈와between 피사체와의 Image Size Focal length of lens 렌즈의 촛점거리

Example) If an거리에 object 20m is photographed with a촛점거리 lens of 50mm focal 예제) 20m 있는away 물체를 2/3" 카메라로 50mm 의 length using a 2/3” camera, the image pick-up range (height) is:

렌즈를 채용하였을 경우의 촬상범위(높이) Lens

X

50mm 6.6mm

20m X=

20,000 x 6.6 50

= 2,640mm

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Chapter 10 Communication

50

수직폭

100

Horizontal수평폭 width

50

20

10 7 5

3

0.7 0.5

50

20

0.3

0.05

3 0.02

2/3"→ 1"→

0.01 7 10 10

20 30 5070100

20 30 5070100

200

200

500 500

리

/

수 직 폭

0.1

0.1

7 5 4

45。

Focal 촛 점length 거리

0.2

0.2

10

Camera-to피사체거 object distance

0.5

0.3

1

Focal length

0.7

0.05

↑ 피 사 체 수 평 폭 Horizontal width of object

Camera-to-object distance (m)

1.0

2

촛 점 거 리

평 폭

2 1.0

100

피 사 체 의 거 리 (m)

수

10 7 5 3 2 1.0

20

0.03 0.02 0.01

↑ 피 사 체 수 직 폭

Vertical width of object

Vertical width 100

Horizontal width/vertical width

② Standard of image pick-up area

3) Minimum illumination The minimum value of illumination shall be greater than 10 or more times of the required illumination conditions so that information on the desired object can be acquired. (2)Wireless I-TV 1) Wireless equipment shall be designed after carefully examining its output, transmission distance and frequency band width. 2) Radio antenna shall be installed in a place of interference-free. 3) Video antenna shall be installed horizontally facing each other. 4) The equipment shall be designed with taking interface with the frequency of the existing radio equipment into consideration in order to prevent mutual interference. (3) Environment 1) Camera shall be installed in a place where it is not exposed to the direct sunshine or strong light. If it becomes inevitable to install the camera in a place exposed to sunshine or other light, appropriate sun shield shall be installed. 2) The focal length of the camera lens shall be calculated by taking into consideration the size of the object and the camera-to-object distance. 3) Lens shall be firmly attached to the camera to prevent separation caused by vibration or impact. The camera accessories and the transmission channels shall be installed in a place away from strong electromagnetic field, while the cable shall be protected by the steel conduit, if necessary.

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4) Camera, monitor and accessories shall be installed in a place with less vibration and/or shock. To protect the camera from external shock, a camera housing shall be used. 5) Preparation to high temperature ① The air cooled, water cooled or electronic cooled type housing shall be installed and keep suitable degree for camera. ② The conduit exposed directly to the heat shall be protected with heat shield plate or heat shield glass tape in order to minimize the damage caused by heat. ③ If the camera housing is directly exposed to heat, compressed air shall be blown to block heat from the front glass of the housing. If necessary, heat-resistance glass shall be installed ④ Air filter shall be provided to supply the fresh air. ⑤ Electronic cooled type housing shall be used in high temperature area, instantaneously. 6.1.2 Paging system 6.1.2.1 Definition of Paging system - Annunciation of operation condition and emergency condition in all facility and in a partially (group). - Annunciation of annual and monthly maintenance - Broadcasting for safety 6.1.2.2 Standard model of Paging system - PBX, Amplifier - Network amplifier - Matrix monitoring (SNMP, Tivoli EIF, Tivoli Enterprise console) - IP Matrix (including LAN) 6.1.2.3 Structure of the Exchanger (1) Type of the exchanger 1) The exchanger shall be IP-PBX type and provided circuit NO. and IPT service without any additional equipment. 2) The exchanger shall be equipped with Non-blocking method, modularized with each function, circuit and the extension shall be done with only additional card without any control equipment. 3) The exchanger and auxiliary equipments (rectifier and battery) shall be connected with serial and LAN in order to doing maintenance and additional service 4) Control system (CPU and memory)and link(Nod) shall have redundancy. 5) Grounding resistance shall be 10Ω below. (2) Components of the exchanger 1) The materials shall be used the international standard type. and the facility shall be equipped with electric specific and mechanical hardness.

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2) The protection device (MCB etc) shall be provided with each power circuit. 3) The connector shall be made so that can be protected miss connection , mechanically. (3) Function of the Exchanger 1) Automatic Attendant Incoming Function(DID/R2 MFC) 2) Direct Attendant Call Function(DOD) 3) Inter call taking function 4) Extension Subscriber Console Dialing Function 5) Extension Subscriber Distance Call Control Function 6) Call transfer function 7) Call pick up function 8) Conference function 9) Signal digit dialing function 10) Camp on function for connection waiting 11) Line Disconnect Function 12) Holding & Call Waiting Sound Send Function 13) Incoming Transfer function 14) Private line service function

6.1.2.4 Rectifier (1) Input voltage: AC 380V, 3 Phase or AC 110/220V, 1 Phase Output voltage: DC 48V± 4 V (2) Input and output voltage shall be marked on the cubicle. (3) Output voltage shall be controlled both manual and auto. (4) Maximum capacity shall be 130% of rated capacity for 1 minute. (5) DB shall be 5 voltages below. (6) Power of battery shall be supplied to the exchanger in case of power failure of the rectifier both manual and auto. (7) Grounding resistance shall be 10Ω below. 6.1.2.5 Battery (1) Maintenance free type battery shall be contained in the cubicle. (2) Output voltage and current shall be marked on the cubicle. (3) Maximum operating hour shall be more than 6 hours. 6.1.2.6 Inverter Inverter(3 KVA) shall be had the following characteristic. (1) Rated output voltage: DC 44- 60V (2) Characteristics - Input voltage: AC 220V - Frequency : 50 HZ (within 5%) - Wave distortion: 5% and below (sine wave) - Voltage variation ratio: within 2% - Adjustable voltage range: 5% and above

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Chapter 10 Communication

(3) Over-current protection - Output current shall be limited within 120% of rated current by current limiter , and have constant current characteristic in order to lower the voltage. 6.1.2.7 MDF MDF shall be equipped with arrester, terminal block and rack. 6.1.2.8 Amplifier part (1) The capacity of the main amplifier shall be calculated after examining the number of speakers to be installed, and the groups to be organized. (2) The main amplifier shall be composed of systems that enable emergency broadcasting or urgent broadcasting. Appropriate system shall be installed between the exchange part and amplifier so that broadcasting can be selected according to functions. (3) To protect the system against heat, vents and fans shall be installed at the back of the amplifier. 6.1.2.9 Handset & Speaker part (1) Prior to designing terminals (handsets), site environment and distance between main systems shall be considered. (Communication distance shall be considered in the case of digital terminals). (2) Wireless, digital or analog type shall be used according to the purpose of use, while desk type, wall-mounted type, or explosionproof type be selected according to the environmental conditions of the area of installation. (3) Speakers shall be designed in consideration of the noise level at site and the installing environment, and specifications shall be decided separately for each operation room, indoor and outdoor, and hightemperature producing areas.

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Chapter 10 Communication

6.2 Standard basis Following equipments shall be supplied and decided after discussing between KRIIndonesia and supplier.

6.2.1

I-TV System

(1) Analog camera Item

Detail

CCD Type

Color CCD

Pick- up device

1/3, 1/2 Inch

Effective pixel

500 TV Line(410,000)

Lens mount type

C/CS Mount

Illumination(Lux)

description

Remarks

Conventional type(0.4 and above) Low illumination Intensity (0.0002 and above) 1Vpp PAL Composite,75Ω/BNC connector

Output

(520Line/ 60field)

Day & Night

Color/BW , Auto Change.

(2) Network camera / Video converter Item

Detail

Video compressed type

MJPEG

Frame rate

30Frame/sec./Ch

Max. NO. of user

10 Clients and above

Connection to Network

Dedicated,100Mbps

Developing Tool

SDK

Connect

WEB

Monitor size

640*480 and above

10-13

description

Remarks

Chapter 10 Communication

(3) CRT Monitor Item Color display Size

Synchronizing

Detail

description

Remarks

PAL only 14 Inch and above, Deflection: 90 degree Inside Synchronizing Outside Synchronizing, In/Out Synchronizing

Effective pixel

350 line and above

Synchronizing frequency

15.734KHZ (Horizontal) Video :0.714Vp-p

Input signal

Synchronous : 0.286 Vp-p Impedance :75Ω

Synchronizing frequency

50 HZ (Vertical)

Operation temperature

–10℃~ +50℃

humidity Input power, Frequency

0 % ~ 90 % AC 110V/220V, 50 HZ High voltage disconnection function

ETC

Control function of color, brightness, shade and density Pre-set function

(4) PDP, LCD Monitor Item

Detail

description

Display type

LCD, PDP

Resolution

1024*768 and above

Brightness

500 cd/㎠

Display type

4:3, 16:9

Viewing angle

Up, Down, Left, and Right 160 degree and above

Signal Input

A/V, S-Video, P/C( Duplicate type)

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Remarks

Chapter 10 Communication

5) Wireless LAN Modem(Long distance) Item

Detail

description

Protocol

IEEE 802.11a,b,g

Access point

Smart AP (Bridge)

Antenna

AP with outer antenna

Distance

1Km ~3Km

Quality

Real time video transmission

Frequency

Americas (FCC) 2.412 to 2.462 GHz : 11 channels 5.15 to 5.35, 5.725 to 5.825 GHz : 12 channels

Remarks

To be met with Indonesian regulation

(6) Wireless Network Equipment (Long distance) Item

Capability : 8.8Gbps and above Interface : 10/100BaseT, FX, 1000Base-SX, LX, ZX IEEE 802.1x, IEEE 802.3x, IEEE 802.1D, IEEE 802.1p, IEEE 802.1Q, IEEE 02.3ab, IEEE 802.3u, IEEE 802.3

• Core/ • Backbone • Switch • •

Capability: 32Gbps and above Interface: 10/100/1000BaseT, 1000Base-SX, LX, ZX Protocol: RIPv1/2, OSPF, EIGRP, IGRP, IS-IS, BGP4 IEEE 802.1x, IEEE 802.3x, IEEE 802.1D, IEEE 802.1p, IEEE 802.1Q, IEEE 02.3ab, IEEE 802.3u, IEEE 802.3

LAN

• • Router

• •

WAN Equip ment

description

• • • •

Access Switch Equip ment

Detail

ATM

Capability : 2Gbps and above Interface: 10/100BaseT, 10/100BaseFX, Token Ring, FDDI, ATM, 1000Base Ethernet Protocol: RIPv1/2, OSPF, EIGRP, IGRP, IS-IS, BGP4, PPP, HDLC, X.25, Frame Relay IEEE 802.3, IEEE 802.10, IEEE 802.5

• •

Capability: 1.6Gbps and above (New Bridge)

• •

Protocol: VOICE, IP, FRAME-RELAY, X.25, CELL RELAY ILMI(Integrated Local Management Interface) and ATM Forum IMA (Inverse Multiplexing over ATM)

• • MSPP • •

Interface: T1/E1 and T3/E3 connection

Capability: 10Gbps and above Interface : 10/100/1000BaseT,1000Base-SX/LX, DS1, DS3, ATM, OC3 ~ OC 192 Protocol: Multi RPR, GFP, VCAT

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Remarks

Chapter 10 Communication

Item Protocol

• • • •

Detail Short loop selection Loop Free Multi-Path VLSM : Subnet

Load Balancer

• • • • •

Capability : 100 Mbps and above Interface: IEEE 802.3 Round Robin, Weighted Round Robin, , Least Connection Multiple Physical& Logical Cluster management Windows NT, UNIX, Netware or Cluster connection

(7) Video Transmitter &Receiver Item

description

Detail

description

Frequency of Transmitter and Receiver

2.410 ~2.470 GHZ

Oscillation Method

Phase Locked Loop Control

Frequency type

F2F

Number of Channel

4 Channels with Dip switch

Output power

10mW (1 W with additional Module)

Reaching distance

1.2Kw/ 10mW, 7~8 km/1 W

Band width

12 MHZ

Impedance of Antenna

50Ωunbalance(BNC)

Antenna type

Parabolic, Yagi, Helical

Video In and output type

VSB(Vestigial Side Band) 1Vp-p, PAL

Video In and output Impedance

75Ωunbalance(BNC)

Audio In and output

0 dBm Stereo

Audio In and output Impedance

10 kΩ Stereo

8) Data Transmitter & Receiver Item

Detail

description

Frequency of Transmitter and Receiver

402 ~ 512 MHZ

Output power Sensitivity

10 mW 12dB, SINAD -0.4V(Signal plus Noise distortion to noise plus Distortion ratio 50Ω Unbalance 0.0005%

Impedance Accuracy

10-16

Remarks

Remarks

Remarks

Chapter 10 Communication

Item

Detail

description

Superiors

Less than – 60dBc

Antenna type

Yagi, Helical

Signal level of data input/output

0.7~ 2.0 Vp-p

Impedance of data input/output

Distance

10 kΩ (BNC) Dial Tone Multi Frequency/RS-232C/ RS-422/RS-485 700m

Operation voltage

DC 12V

Communication

(9) Power Station Item

Detail

description

Input Voltage

AC 85 ~ 264V, 50HZ ± 10%

Output Voltage Output Current

DC 12V 1.2A

Efficiency of input voltage

73% Typical

Ripple

120mVp-p Max.

Remarks

Remarks

(10) Camera Controller (TX,RX) Item

Detail

description

External communication

RS-422, RS-485, Non-synchro

Remote control

RS-422, RS-485, Non-synchro, Duplicate type

Control signal output

AC250V, 7A (3 points x 4 sets)

Output Impedance

10kΩ

Function

TX : Camera 99sets, Aux 1circuit, Zoom, Pan/Tilt RX : Camera 4sets, Aux 1circuit, Zoom, Pan/Tilt

Input Voltage

TX: AC110V/220V, RX: 9V DC

(11) Desk Controller Item

Detail

description

Output of signal

0.7∼2Vp-p Dial Tone Multi Frequency Data

Output Impedance

10kΩ

Control Circuit Input voltage

Quad-3 circuits, Camera 12sets, Aux 3circuits, Zoom, Pan/Tilt 12VDC

10-17

Remarks

Remarks

Chapter 10 Communication

(12) Multi Encode Process Item

Detail

description

Remarks

Input

RS-422, RS-485, Non-synchro, Duplicate type

Output

RS-422, RS-485, Non- synchro, Duplicate type

Control Signal

2 Input, 1 Output, 2 Channel

Input voltage, frequency

AC 110/220V, 50Hz

(13) Electronic cooling device Item

A type

B type

C type

Efficiency

100W (86kcal/hr)

100W (86kcal/hr)

100W (86kcal/hr)

Input voltage

DC24V 13A

DC24V 13A

DC24V 13A

Cooling fan(outside)

DC Brushless DC24V 0.3A×2EA

DC Brushless DC24V 0.3A×1EA

DC Brushless DC24V 0.3A×2EA

Cooling fan(inside)

DC Brushless DC24V 0.3A×2EA

DC Brushless DC24V 0.3A×1EA

DC Brushless DC24V 0.2A×1EA

272x200x25

250x153x38

200x138x30

235x174x33

170x98x30

170x98x30

Cooling Fin(outside) (mm) Cooling Fin(inside) (mm)

(14) Housing (Air or Water cooled type) Item Type Consumption/Pressure of cooling water Consumption/Pressure of cooling air

Detail

description

Water cooled and Dust proof type 10 ℓ and above, 1~2 kg/㎠ 1 ~ 32 kg/㎠, 1 N ㎥/min and above

Ambient/Operating air temperature

40 ~ 110 C°/ 40 C° and below

Function

Protection of camera and lens

Bracket, Sight glass

Semi-fixed angle bracket, Tempered glass

10-18

Remarks

Remarks

Chapter 10 Communication

(15) A.V.R (Conventional type) Item

Detail

description

Capacity

3KVA

Input voltage, frequency

AC 220V 1ph/440 380V 3ph, 50Hz

Output voltage, frequency

AC 110/220V, 50Hz

Stability

±2% of Rated voltage

Variation of frequency

0 ~ 0.3%

Interrupt by Harmonic

Protection device

Efficiency

95% and above(single winding type),

Remarks

90% and above(Double winding type) Response speed

Within 48mSec(at 10% variation of Input power)

Phase

Single/ Three phase

(16) A.V.R (Industrial type) Item

Detail

description

Capacity

3KVA

Input voltage/frequency

AC220V within ±30%/50Hz

Output voltage/frequency

AC220V/ 50Hz

Stability

±1% of Rated voltage

Wave distortion

1% and below

Interrupt by Harmonic

Protection device

Efficiency

85%

Response speed

Within 10m/Sec

Phase

Single phase

Remarks

(17) QUAD Item

Detail

Rated voltage/Frequency

AC 110/220V/ 50Hz

In/Out signal of Image

1Vp-p

Connector type

BNC

Input Channel

4CH

Output Channel

1CH

Power Consumption

12W and below

10-19

description

Remarks

Chapter 10 Communication

(18) Desk Controller Item Output of signal Output Impedance Control output signal Input voltage

Detail description 0.7∼2Vp-p Dial Tone Multi Frequency Data 10kΩ Quad-3 circuits, Camera 12sets, Aux 3circuits, Zoom, Pan/Tilt

Remarks

12V DC

(19) Multi Encode Process Item

Detail

description

Input

RS-422, RS-485, Non-synchro, Duplicate type

Output

RS-422, RS-485, Non- synchro, Duplicate type

Control Signal

2 Input, 1 Output, 2 Channel

Input voltage/frequency

AC220V/ 50Hz

Remarks

(20) C.P.U Item

Detail

Input voltage/Frequency

AC 220V/ 50HZ

Power Consumption

18W(±2)Max.

voltage of mother board

DC 5V

Mother board Mpu Osc

11.0592Mhz

Communication

RS-422

Baud rate

9600bps

Max. number of Camera

36 sets

Max. number of Monitor

8 sets

10-20

description

Remarks

Chapter 10 Communication

(21) Matrix Item

Detail

description

Input voltage

AC 6V

Power consumption

60W MAX. (In/output Card 128 By 40)

voltage

DC 5V

of mother board

Power consumption of Mother

Remarks

10W

Board Communication

RS-422

Baud rate

9600bps

Max. number of Camera

64EA

Max. number of Monitor

64EA

Outfit type

Rack Type

(22) ID Time Generator Item

Detail

description

Input voltage/Frequency

AC 220V/ 50Hz

Power consumption

20 W

Video input

16 sets

Video output

16 sets

Communication

RS-422

Baud rate

9600bps

Output Video Signal

1.0Vp-p Max. Composite Signal

Input Card per card

1 set

Monitor output number

1 set

Max. letter input

16 letters(Korean, English, Special, etc)

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Remarks

Chapter 10 Communication

(23) ID Time Generator Card Item

Detail

description

Input voltage

DC 5V

Power consumption

0.5W Max (per Output Card 1set)

Output Video Signal

1.0Vp-p Max

Input Card per card

1 set

Monitor output number

1 set

Max. letter input

16 letters(Korean, English, Special, etc)

(24) Multi Process Unit Item Video control

Composite Signal

Detail

description

1024 Video control, Auto/Manual selection, 1~64 second Interval 1023 Video & Receiver control,

Receiver control

Camera/Light/Aux1/Aux2.. Power control, PT/Lens control, Preset control, Sensor Data Receiving(8 Point) 256 Alarm Point Control,

Alarm control

256 Point Alarm Lamp Out, 2 Point Alarm Link, 1 Alarm Relay Out Receiver Port (RS232/RS485),

Communication

PC Port (RS232 / RS422), 3 Control Port (RS232/RS422)

Input voltage/Frequency

AC 220V(within 10% ) / 50Hz

Power consumption 10 W and below Outfit type

Remarks

Rack type

10-22

Remarks

Chapter 10 Communication

6.2.2 Paging System (1) Audio IP Matrix Item

Detail

description

Remarks

- Audio transmission between IP Matrix and Network Audio

- Standard Ethernet (IEEE802.3)

Protocol

- Real time audio transmission - Cobranet

PBX

- Standard PBX, E1, E&M, LOOP method

Extension

- Module extension if extension is required

Amp. assistance

- Analog Amp. connection

Remote

- IP Matrix with Diagnostic function

monitoring

- SNMP

(2) Amplifier Item

Detail

description

Type

Power Amplifier & Unit or Incremental

Power consumption

50W, 100W, 150W, 200W,…, 1,000W and above

Remarks

(High Impedance) Input voltage/Frequency

AC 220V±10%/ 50Hz

Input Noise Level

0 dB and below

Signal to Noise Ratio

60 dB and above

Frequency Range

300Hz∼6,000Hz ±3dB

Resistance

2MΩ and above

Speaker cable

Shield cable 2.0mm2 x 2C / group

All Paging Channel

All Paging : 1 Channel

Group Paging Channel

Group Paging : 3∼16 Channel

Operating temperature, humidity 0∼40℃, 10∼90% Cooling method

By Cooling Fan

Emergency power(back-up)

2 hour and more

Broadcasting

Total

All Amplifier on condition

Group

Amplifier for Group On condition.

Group Selecting

Amplifier shall be selected

10-23

To be met with Indonesian regulation

Chapter 10 Communication

(3) Main Power

Main Power

Battery

Others

Item Capacity Components Control

Detail

description

Input voltage Frequency Output voltage

Decided by the requirement Electronic equipments and power supply SCR control & TCC method 3phase AC 380V or 1phase 220V ±10% 50Hz ± 3Hz DC 48V ±2V and below, 100A

Changing range of load

85% and above

Capacity

Decided by the requirement (40, 60, 80, 120, 160AH)

Type

Maintenance free

Output voltage/Capacity Frequency Transient response

12V, 24V, 48V, 2 hour or 6 hour and more 300∼3,400 HZ : within 5mVrms Within 10% , within 250msec

Current protection

110%±10% of rated current

Over voltage alarm Over voltage trip

60V±0.5V of output voltage

Remarks

65V±0.5V of output voltage

Under voltage protection 43.5V±0.5V of output voltage

(4) Handset Item

General

Analogue Handset Digital Handset

Detail

description

Communication Call Signal Operation

Handset and Hand free Signal Tone/ Voice Ceiling Type Pulse Code Modulation Digital Signal Push Button Type

Keypad

Digital : 22 Push Dial, Analog : 15 Push Dial

Impedance Operation temperature Type

1200Ω, Balanced

Location

Distance(1km and more) from main

Function Type Location

Individual communication, Broadcasting Desk & Wall(Handset Box) Distance(within 1km) from main

Function

Multi function, Display , etc

0∼40℃ Desk & Wall(Handset Box)

10-24

Remarks

Chapter 10 Communication

(5) TRS wireless transmitter 1) Movable type Item

Detail

description

Range of frequency

380 ~ 430MHz

Power consumption

3W

Capacity of battery

1850mAH

Weight

243g and below

Display

Color

Language

Korean, English

Others

Included microphone & speaker

Remarks To be met with

Indonesian regulation

2) Fixed type Item

Detail

description

Remarks

Range of frequency

380 ~ 430MHz

To be met

Power consumption

5 W and below

with

Operation degree

-30℃ ~ +60℃

Indonesian

Weight

1370g and below

Protection

IP54

Shock, drop and vibration

MIL 810 C/D/E/F

Voice Services Supported

Telephone Call(PABX/PSTN)

regulation

7.0 Test and inspection standards The supplier shall conduct the following tests, and submit the results of the test and inspection to KRI in a bound-book form when products are delivered. 7.1 Test and inspection under manufacturing For major parts, whether an attended inspection should be conducted for the following items shall be decided based on a discussion between KRI and the supplier. Unless such inspection is requested by KRI, the supplier shall carry out its own tests and the test report shall be submitted and approved by KRI. 7.1.1

Inspection of appearance, size and manufactured state for each purchasing parts Appearance, size and manufacture inspection shall be carried out by the supplier during the process of, and after, purchasing materials. For inspection of important parts, an inspector from KRI shall attend the inspection. However, inspection standards shall satisfy the allowable error shown on drawings or, in case of

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Chapter 10 Communication

standardized products, on its applicable standard. 7.1.2 Inspection of manufactured parts The supplier shall conduct its own inspection based on check lists; however, an inspector from KRI shall attend the inspection carried out for important parts. 7.1.3

Inspection of partial fabrication and provisional fabrication Immediately prior to fabrication at plant and prior to delivery after fabrication, the supplier shall conduct a test and inspection in the presence of an inspector dispatched by KRI.

7.2 Incoming inspection The incoming inspection shall be conducted when materials are brought in prior and be approved by KRI. 7.3 Preliminary Acceptance Test 7.3.1

The supplier shall, prior to conducting PAT, submit the PAT check sheets to KRI- Indonesia for approval.

7.3.2

The supplier shall conduct PAT for communication equipment under no-load state. Upon completion of the test, the supplier shall submit a test report to KRI according to the contract specifications, and KRIIndonesia shall issue Preliminary Acceptance Certificate if the results of PAT are satisfactory.

7.4 Final Acceptance Test FAT of communication facilities shall be carried out upon completion of PAT. The Final Acceptance certificate issuing conditions are as follows: Hardware shall satisfy 99.7% or more of availability ratio in continuous operation for 720 hours; and the hardware and software shall satisfy performance required by contract. 7.5 Warranty 7.5.1

The warranty period shall be 1 year from the date FAT --- > (shall be defined at contract) is successfully carried out; however, the period may be adjusted according to the characteristics of the equipment through discussion between the supplier and KRI. If any trouble occurs during this period, and unless the causes of such trouble are attributable to KRI, the supplier shall immediately repair the trouble for account of the supplier.

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Chapter 10 Communication

7.5.2

Actual warranty method shall be included in the estimate sheet.

7.5.3

The warranty conditions shall also be specified in each specification.

7.6 Others 7.6.1 The supplier shall obtain KRI approval on all test and inspection procedures. 7.6.2 If the supplier conducts an inspection in the presence of an inspector dispatched by KRI, the supplier shall submit the inspection report to the attending inspector for confirmation. 7.6.3 If the KRI’s inspector requests test and inspection to be carried out by public institutions, the supplier shall comply with such request at its own expenses.

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Chapter 11 Civil and Building Works

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Chapter 11 Civil and Building Works

Table of Contents 1.0 General ........................................................................................................................

4

1.1 Scope of application ..........................................................................................

4

2.0 Civil works ..................................................................................................................

4

2.1 Load ......................................................................................................................

4

2.2 Structure plan ...................................................................................................

7

2.3 Reinforced concrete design ..............................................................................

9

2.4 Steel structure design ........................................................................................

10

2.5 Footing foundation design ...............................................................................

10

2.6 Plant ground level standards ...........................................................................

12

2.7 Load application points, sizes, and types ......................................................

12

2.8 Common ducts ....................................................................................................

13

2.9 Designs of steel tube piles foundation ..........................................................

13

2.10 Drain design........................................................................................................

15

2.11 Track design ........................................................................................................

18

2.12 Road design .........................................................................................................

18

2.13 Others ...................................................................................................................

18

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Chapter 11 Civil and Building Works

3.0 Building works ...........................................................................................................

21

3.1 Building basic planning ...................................................................................

21

3.2 Building structural planning ...........................................................................

37

3.3 Building finishing planning ............................................................................

48

3.4 Painting ...............................................................................................................

49

3.5 Doors and windows ...........................................................................................

49

3.6 Ventilation and dust prevention ...................................................................

50

3.7 Condensation prevention .................................................................................

50

3.8 Soundproofing ..................................................................................................

51

3.9 Heat resistance ....................................................................................................

51

3.10 Fire fighting ........................................................................................................

51

3.11 Waterproofing and roof drainage ...................................................................

52

3.12 Safety facilities .................................................................................................

52

3.13 Lighting

............................................................................................................

52

3.14 Sanitary system and plumbing ......................................................................

52

4.0 Fabrication of steel structures .................................................................................

54

4.1 General .................................................................................................................

54

4.2 Materials ..............................................................................................................

54

4.3 Shop drawings and full-size drawings ..........................................................

55

4.4 Machining ...........................................................................................................

55

4.5 Welding ................................................................................................................

57

4.6 Temporary fabrication ......................................................................................

61

4.7 Painting ................................................................................................................

61

4.8 Packing .................................................................................................................

61

4.9 Fabrication inspection and test standards ...................................................

64

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Chapter 11 Civil and Building Works

1.0 General 1.1

SCOPE

1.1.1 This specification covers the design criteria for civil and building works and design, and the fabrication of structural carried out for the KRI. . The term ‘Design Criteria’ includes loading standards, permissible stresses, permissible deflection, functional requirements and quality standards to be adopted as a basis for preparation of designs and drawings by the Contractor. These designs and drawings will cover buildings for production and non-production facilities, auxiliary buildings and structures, foundations for buildings and equipment, drains, sewers and other miscellaneous civil engineering items of work to be provided and/or to be modified/ rectified by the Contractor. 1.1.2.The designs prepared by the Contractor shall not only provide for the requirements indicated in this specification but also consider the overall process requirements, service conditions and provisions to be made for future expansion. The designs shall be compatible with the operating conditions in the plant and the atmospheric conditions prevalent at Tenggara, Sulawesi, Indonesia. Standards and unification shall be carried out to the maximum extent possible and in the interest of standardization. 1.1.3 In case of any discrepancy among the codes/ standards, “Civil & Architectural Design Criteria” has a priority and International Design Codes and Standards can be used with approval of KRI –Indonesia. In principle, the design criteria for civil and architecture works shall be in accordance with “Civil & Architectural Design Criteria” approved by the KRI –Indonesia.

2.0 Civil works 2.1 Load 2.1.1

Outline Provisions of Part 4 Design conditions, Common Technical Specification, ISZ-1 shall be applied. (1) Earth pressure The earth pressure acting upon the retaining wall or underground structures shall

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Chapter 11 Civil and Building Works

be calculated based on Coulomb & Rankine theoretical formula. (2) Load of machinery 1) The weight of equipment and materials shall be treated as long-term load

based on the data submitted by the supplier. 2) The weight of the products or materials which pass through another equipment or are placed on such equipment shall be regarded as long-term load. 3) The impact of the machines or equipment under operation shall be included in live load. 4) Load of machines during the process of installing or during commissioning shall be treated appropriately according to each situation. (3) Unit weight

( Materials

Weight(kg/m3)

Steel Cast iron Reinforced concrete Plain concrete Cement mortar Asphalt pavement Stone Wood

7,850 7,250 2,500 (2,400) 2,350 (2,300) 2,150 2,300 2,600 800

): Architectural

2.1.2 Load Condition (1) All foundations and concrete structures, shall be designed to resist full operating dead and live loads, with appropriate combination of wind and seismic forces and with due allowance for impact, inertia loading, vibration etc as secondary affects of live loads, temperature variation etc, according to “Civil & Architectural Design Criteria” approved by the KRI –Indonesia. . While designing structures and foundations either the effect of seismic forces or wind loads, whichever produces the worst effect, shall be considered along with usual load conditions. (2) Concentrated and uniformly distributed live load on floors and platforms shall be considered depending upon the usage and in accordance with maximum expected process requirements, to be indicated by the equipment manufactures. When the loads are movable, they shall be so placed as to get worst effect in moment, shear, axial

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Chapter 11 Civil and Building Works

loads etc for which the elements shall be designed. The effect of concentrated load shall not be reduced. Due allowance shall be made, wherever necessary, for installation and operation of any equipment as per equipment manufacturer’s data and recommendations. The design shall be based on the maximum loading due to uniform live load and/or equipment loading including impact, vibrations etc. (3) Design wind pressure and forces shall be as per the provisions of “Civil & Architectural Design Criteria” approved by the KRI –Indonesia. Design for tall slender structures such as towers, chimneys etc shall take into consideration the forces included by wind excited oscillations. Aero-dynamic stability of such structures shall be established. (4) Seismic forces shall be considered according to the provisions of UBC 97 or SNI-1726-2002. Modal analysis will be necessary in case of stack like structures in accordance with UBC 97 or SNI -1726-2002. (5) Members subjected to high temperature variations shall be designed to withstand the stresses arising out of such temperature variations. (6) Design of structures shall provide for temporary loads which may be lifted during erection and maintenance of plant and equipment. Consideration shall be given in the design of structures to the contributing loads from piping and cabling including provisions for piping anchors and dead endings of electrical conductors. (7) Supporting structures and foundations for equipment which may cause vibration, shall be designed for the dynamic effect of equipment together with the direct loads. The dynamic loads and other relevant data required for analyzing. The dynamic effect shall be taken as per manufacturers’ data and recommendations.

2.2 Structure plan 2.2.1

Examination on future extension (1) If the structure is expected to be expanded in future, the effects on the future works and the current equipment shall be considered. (2) If investment is made with a plan to expand equipment in future, safety, workability and economical efficiency shall be examined to adjust the range of works and designs.

2.2.2

Foundation settlement (1) Total settlement shall be classified into immediate settlement and consolidation settlement, and allowable settlement determined according to the shapes and types of structures. Settlement shall not exceed the allowable limit. (2) If the settlement and the soil bearing capacity exceed tolerance, a foundation

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Chapter 11 Civil and Building Works

type considering the soil characteristics shall be examined and applied. 2.2.3 Thermal stress Structures exposed to hot environment shall be examined to determine effects of thermal stress. 2.2.4

Vibrating machinery Machines producing vibration, such as rotary equipment(turbine, generators, motors); reciprocating machines(engines, steam engines, piston type pumps and compressors); and impact producing machines(material crushers, forging hammer and dropping machines), shall be examined to determine vibration based on the following: (1) Machine must be able to operate effectively without excessive wear on the designed machine foundation. (2) The foundation shall be free of damage or settlement so that machine can fully demonstrate their functions. (3) Vibration transmitted to earth by the machine shall not adversely affect human, nearby structures or the production process of sensitive machines.

2.2.5 Drainage In an area where machines use large amount of water, appropriate slopes and water drainage system shall be installed to ensure efficient machine operation. 2.2.6 Sump pit Sump pits used to discharge water and oil shall be installed at specific intervals in areas where the underground structure characteristics and level are changing. 2.2.7 Chemical resistance (1) Structures exposed to acid or alkali shall be properly installed to withstand chemical effect. (2) Port facilities shall use concrete carrying strong seawater resistance. 2.2.8

Abrasion resistance Appropriate abrasion resistance measures shall be considered for structures vulnerable to abrasion.

2.2.9 Dust prevention Equipment exposed to dust shall be properly protected with proper methods and construction materials. 2.2.10 Others Matters pertaining to paintings and safe facilities shall be governed by the provisions of Paragraph 3.0 Architectural works, Chapter 11.

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Chapter 11 Civil and Building Works

2.3 Reinforced concrete design 2.3.1 Design method (1) For calculation purpose ‘Ultimate Strength Design Method’ or ‘Working Stress Design Method’ may be adopted, but design shall be consistent throughout. (2) If the strength design method is used for the reinforced concrete structures, not only the strength with respect to deflection, tension, compression, shear and distortion but also the durability relating to the sagging, cracks, fatigue and vibration of the structure shall be reviewed. (3) Structural members shall be designed taking into consideration the overall loads including the dead load, live load, wind load, earthquake load and horizontal load, as well as the pre-stressing, crane load, vibration, impact, contraction, temperature change, creep, and effects of uneven settlement. (4) Load coefficient and strength reduction factors shall conform to the regulation governing strength design method. (5) Structures and members shall carry design strength exceeding the required strength calculated in all sections. (The required strength shall be calculated based on the combined load specified in the digitalized load and standards.) (6) Concrete work shall secure a dense, homogenous, smooth mass including required finishes, possessing required strength and resistance to weathering and abrasion for the structures and foundations. 2.3.2 Steel bars for concrete reinforcement (1) Strength of reinforcing bar The strength of reinforcing bar strength shall be governed by the standards of SNI 03-2847-2003 or equivalent international standards. (2) Except for the pre-stressed tendon, the design standard yield strength, fy, of the

reinforcing bar shall not exceed 400 N/mm2 for deform bars. and 240 N/mm2 for plain bars. 2.4 Steel structure design Provisions of Paragraph 3.2.4 Steel structure design, Chapter 11 shall be applied. 2.5 Footing foundation design 2.5.1 Foundations for structures and equipment shall be proportioned to resist the worst

conditions of loadings and shall be generally designed as per the provisions of “Civil &

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Chapter 11 Civil and Building Works

Architectural Design Criteria” approved by the KRI –Indonesia. 2.5.2 Structures and foundations for supporting vibrating, rotating and reciprocating equipment shall be designed to avoid resonant frequencies In the event that such equipment is installed above ground level, the supporting structure and foundation shall be investigated also for natural frequency and designed properly to avoid resonance and shall be within allowable amplitude. 2.5.3

The depth of foundation shall be determined based on loadings on foundation, safe bearing capacity at the founding level, constructional and technological requirements. The maximum allowable bearing concrete shear for design of foundation shall correspond to soil data/soil strength values indicated in detailed soil investigation report taking into account limits of allowable settlement considered for design of structures and equipment.

2.5.4

Ground bearing capacity and settlement (1) The foundation soil bearing capacity and estimated settlement of the foundation shall be calculated based on materials obtained from the ground and soil test, and the existing materials. (2) The soil bearing capacity shall apply minimum safety factor (long-term load FS 3.0), and the estimated settlement shall be within the allowable settlement.

2.6 Standards of plant floor level The plant floor level shall be designed based on the standards shown in the following figure. However, for the basement and other adjacent plants where rainwater is likely to enter, the floor levels may be designed differently. FL = GL + 300mm

FL

300mm GL(지반고) GL (Ground level)

2.7 Loading points, sizes and types The designed load application points, sizes, and types shall be specified.

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Chapter 11 Civil and Building Works

2.7.1

Loading point

2.7.2

Sizes and types Size

Loading Point

Load

Remarks Vz

Hx

Mx

My

Dead load Operating load Wind load Earthq. Load RPM Eccentricity Eccentric load

Dynamic load

2.8 Pipe utility conduct The minimum height of pipe utility conduct shall be at least 2.2m, and shall be installed as follows: C

Maker

B

A

D

A : 통로 - 800 m A: Path – 800mm B : CABLE - 200mm m B : Cable - 200mm 배관 - 200mm Piping – 200mm C : CABLE - 300mm C : Cable - 300mm 배관 - 배관배열 Piping – Piping arrangement 정비조건을 고려 Maintenance conditions shall be considered. D : CABLE TRAY사양 및 배관 D: Cable tray specifications and pipe arranging conditions 배치조건 기준( 소화, 살수배관) (fire-fighting, and water spray facilities)

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Chapter 11 Civil and Building Works

2.9 Piling 2.9.1 Application (1) Steel pipe pile & PC pile shall be used for steel plant of KRI. ; however, other types of materials may be used for reasons of workability, economical efficiency, and stability. (2) In case the soil bearing capacity and settlement of the super structure supported by the spread foundation exceed the allowable bearing capacity and the allowable settlement, the steel pipe pile foundation shall be applied to the super structure. (3) The pile bearing capacity shall be adopted as the lesser value between the soil bearing capacity and the pile material stress value (4) If compressive soil layer exists, the negative skin friction reacting upon the pile shall be considered by pile bearing capacity calculation. (5) The short-term bearing capacity shall be 1.5(KS), 1.33(PT.KE)times the long-term bearing capacity. 2.9.2 Allowable bearing capacity of pile (1) steel plant of KRI The allowable bearing capacity of the pile is decided based on the results of loading test (L ≒ 20m) conducted at the site of steel plant of KRI The allowable bearing capacity of the pile not shown on the Table shall be calculated using the values shown on Table as reference.

Pile types

Pile size

Material quality

Long-term allowable bearing capacity (Vertical) According to Pile Load Test

According to Pile Load Test

Steel pipe

Φ508.0Χ9.5thk. Φ558.8Χ9.5thk.

SS-400

000 t/ea 000 t/ea 000 t/ea 000 t/ea

PC

Φ400.0Χ75thk. Φ500.0Χ90thk. Φ600.0Χ100thk.

Prestressed Concrete k-600

000 t/ea 000 t/ea 000 t/ea 000 t/ea

(fc’=50 N/mm2)

※The above allowable bearing capacity may vary with the pile length and soil conditions

2.9.3 Laterally loaded pile

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Chapter 11 Civil and Building Works

(1) The bending stress occurring on the pile shall not exceed the allowable bending

stress of the pile materials. (2) The pile head displacement shall not exceed the allowable displacement decided

according to the super structure. 2.9.4 Tension pile The pile being affected by the wind load or Earthquake Load or lifting power shall be designed taking into consideration of the tensile stress and the effects on joints of the pile materials, and the upward displacement of the pile head. 2.9.5 Pile spacing (1) The distance between the pile centers shall be more than 2.5 times the diameter of the pile head. (2) The distance between the pile center and the edge of the foundation shall be more than 1.2(PT.KE), 1.25(KS) times the diameter of the pile head. 2.9.6 Pile joints (1) The joint of pile shall be determined based on the results of soil test. Joints of the steel pile shall be welded. (2) The bearing capacity of pile per one joint shall be reduced by 5%. When pile load test is executed, the reduction ratio shall be considered. 2.9.7 Pile head reinforcement (1) The reinforcement of the pile head to be embedded within cap concrete shall render positive connection between the pile and the cap concrete, transmitting vertical and horizontal loads to the entire part of the pile group. (2) Detailed matters shall conform to the KRI’s standard drawings of civil. 2.10 DRAINAGE 2.10.1 Intensity of rainfall (steel plant of KRI) Since the intensity of rainfall is not uniform throughout the storm period, formula about the intensity of rainfall should be used according to SK SNI M-18-1989 F, Method of Calculation of Flooding Debit, such as TALBOT Method, SHERMAN Method, ISHIGURO Method. 2.10.2 Run-off coefficient

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Chapter 11 Civil and Building Works

Roof

Road

Raw material yard

0.9 for flat roof, 0.95 for slope roof

0.80 for Asphalt, 0.9 for concrete

0.45

Railroad

0.2

Flat land

Gravel paving

Turf and grass area

0.1

0.2

0.15

2.10.3 Calculation of run-off volume

1  360 Where, Q C I A Q

C I A : Peak runoff volume at the point of design (m3/sec) : Run-off coefficient : Intensity of rainfall (mm/hr) : Catchment area (ha)

2.11 Design standards for Roads

2.11.1

Standard design cars The following basic data for vehicles shall be used for the road design. (Unit: m) Lf

Lr

Minimum radius for rotations

Vehicles

Length

Width

Height

Axle distance

Small car Medium and large car Semitrailer Tractor

4.7 13.0

1.7 2.5

2.0 4.0

2.7 6.5

0.8 2.5

1.2 4.0

6.0 12.0

16.7

2.5

4.0

Front 4.2 Rear 9.0

1.3

2.2

12.0

※Axle distance : Distance between the front wheel axle center and the rear wheel axle center Lf : Distance between the car front section and the front wheel axle center Lr : Distance between the car rear section and the rear wheel axle center 2.11.2 Design speed (1) Maximum design speed within the plant compound shall be 60km/h. 2.11.3 Traffic lanes and roadways (1) The number of lanes shall be determined based on the road function, topographical layout, and traffic. (2) The minimum lane width shall be 3.0m. (3) For the purpose of maintenance of special road, the road width shall be decided based on estimated traffic, vehicle data, work safety and easiness. In such case,

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Chapter 11 Civil and Building Works

special conditions shall be indicated on drawings. 2.11.4 Road classification (Unit: m) Class

Total width

Road width

A B C D

45.0 23.5 12.5 8.5

31.0 21.5 10.5 7.5

2.11.5 Radius of curve Radius of curve shall be decided considering the design speed and the basic data of vehicles. 2.11.6 Longitudinal slope Shall be less or same than 10% 2.11.7 Transverse slope Shall be 1.5% or more not exceeding 2.0%.

2.11.8 Standards truck load (1) Car load(DB) Clearance 차선폭 및 and 여유폭 LaneLoad widthlane andwidth clearance width

(1) Wheel load (DB)

0.1W

0.4W

0.4W b2

b1

a

0.1W

V

0.4W

0.6

0.8W

4.2m

0.8W

0.2W

3.0m

0.4W

1.8

0.6

W : Weight for design vehicle

W : 설계차량하중 W: Load for a design vehicle V : Variable spacing유발하는 which produces V 최대응력을 윤거 stress V: Wheel inducing the maximum maximum stresses(4.2m to 9.0m) (4.2m~9.0m)

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Chapter 11 Civil and Building Works

Load

Total weight (t)

Front wheel load (kg)

DB-24 DB-18 DB-13.5

43.2 32.4 24.3

2,400 1,800 1,350

Middle wheel load (kg)

Rear wheels load (kg)

Wheel contact width (a) (cm)

Front wheel width (b1) (cm)

Rear wheel width (b2) (cm)

9,600 7,200 5,400

9,600 7,200 5,400

20 20 20

12.5 12.5 12.5

50 50 50

(2) Concentrated lane load(DL)

Items not included in this manual shall be governed by the provisions of Korea Highway Specifications. Concentrated load Uniform load

Load

Concentrated load

Uniform load (kg/m)

Moment(kg)

Shear(kg)

1,270 950 710

10,800 8,100 6,080

15,600 11,700 8,700

DL-24 DL-18 DL-13.5 (3) Heavy cars

Cars

Car length (m)

Car width (m)

Load (ton/m)

Wheel load (ton/wheel)

ET Car (152ton)

13.4

2.9

3.9

5.43

ET Car (240ton)

14.35

2.9

5.77

7.5

ET Car (240ton)

11.0

3.45

6.32

10.0

2.12 Others

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Chapter 11 Civil and Building Works

(2) Concentrated lane load (DL) Concentrated road

2.12.1 Clearance between rolling stocks Uniform and road buildings (1) The minimum distance between cars and buildings shall be governed by the provisions of Paragraph 2.11 and 2.13. (2) Separate measures shall be taken for the casting house of the blast furnace. 2.12.2 Minimum height of the structures on road (1) The minimum height of the structures on road, such as the pipe racks for the gas and steam lines, shall satisfy the following specifications: The minimum height of the structures on road shall be as shown in the following Figure:

Depth of Depth

Required Height Minimum height

Height

Cargo height of object

Allowance 0.3m 0.3m Clearance

crossofbeam

Timber

G.L

(2) Required height of the structures on road by major transportation route

Route

Required height(m)

BOF shell transportation route Transformer transportation route Sintering hopper, blast furnace hot stove stator route Plate mill shear transportation route

3.0 Building works

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12.0 8.0 6.0

Chapter 11 Civil and Building Works

3.1

Building Basic Planning

3.1.1 Main building (1) Planning

The overall plan (size : length, width and height)of main building shall be decided to satisfy the condition of machines and equipment, materials, parts, product flow, transporting methods, and the working methods on the basis of plant production plans according to the characteristics of each equipment. (2) Floor height and roof slope 1) Top of crane rail (TOCR): Effective height of machine + Lifting height of overhead

crane Eave height: TOCR + Crane trolley height + Clearance limit(500mm) +Truss height ※ At the steel making and continuous casting plant, clearance limit is decided considering the installing of crane grab. The minimum slope of the plant building roof shall be 3/100 or more when the colored roofing sheet V-500 or W-255 type is used, or 10/100 or more when V-115 is used. The roof slope of the blast furnace casting house, sintering plant and soaking pit yard buildings shall be 35/100 or more.(Not Decided)

2)

b

f

c d

3)

f

a

b

c

a

e

Machines

* Explanatory notes A: Top of crane rail (TOCR) a. Equipment height b. Working space (1500mm) c. Crane lifting height (material and wire length) d. Distance between the crane rail top and the hook e. Elevator height f. Distance between the elevator top and the hook B: Height of the crane trolley top C: Height from top of trolley to the bottom of truss (Construction gauge: 500mm) D: Truss height H: Building height (=A+B+C+D) (Elavator’s height and stuff being moved by crane shall be cross checked)

3.1.2

Auxiliary building

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Chapter 11 Civil and Building Works

(1) Building classes Building name Electricity control room General office Bldg and service room Operation room Warehouse Bath room,Toilet

others

Planning elements Transformer room, switch board room, control room MG set room, thyrister room, and motor room General offices, inspection rooms, laboratories, maintenance room, and conference rooms Operation rooms, control rooms, instrumentation rooms, and computer rooms Material warehouses, parts warehouses, tool rooms, and central warehouses Locker room, boiler rooms, dressing rooms, bath rooms, wash room, and toilets -Septic tanks shall be constructed separately. Pump room, comp. room, blower room and etc.

(2) Electrical control building 1) Planning The Plan should be sized in accordance of the local regulations firstly. In case there is no special local regulations, the below criteria should be applied. ①Building length : Electric panel length + effective passage width(600mm) ②Building width : Electric panel width + electric panel door + effective passage width(600mm)

a

b

c d bd

c d b

b

* Explanatory notes A ( a + b) : Building length B (b +c+ d) : Building width a(가): Electric panel length b(나): Effective passage width (600mm)

a

b

c

b d

c(다): Electric panel width d(라): Panel door width

2) Floor height ① Reference floor height : Required zenith height + required air-conditioning facility height + beam ② Required zenith height : Minimum zenith height 2.4m or more, or larger value of

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Chapter 11 Civil and Building Works

a

a

b

c e d f

the electric panel height and the required height during maintenance (400∼600mm)

* Explanatory notes A: Zenith height a.: Panel height b: Working space (500mm) c: Zenith frame and lighting installation (100mm) d: Duct height e: Duct heat insulation covering height (50mm) f: Girder height B: Ceiling height H: Eave height (= A + B)

(3) General office building and service room 1) Planning

The size of general office and service room buildings shall be decided based on the following data: 2

① Net office area required : 5.0 m /person 2 2 ② Conference room : 2.0 m /person, locker room : 0.9 m /person 2 ③ Required area (including common area) : 6.5 m /person(Common area : Corridor,

stairs ,toilets, and resting rooms) ④ Common passage width within office building : 900~1200mm ⑤ Main passage width within office building : 1200~1500mm ⑥ Toilets -Urinals : 1 unit per 15 persons, or 1 unit per floor area of 180 m2 of the reference floor -Wash basin : 1 unit per 15 persons, or 1 unit per floor area of 180 m2 of the reference floor

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Chapter 11 Civil and Building Works



Wall-mounted urinals







Western-style urinals

Stools

Wash basins

b 1d c e

2) Floor hight ① Reference floor height (3.6m∼3.9m) : Effective ceiling height + required height of construction facility + beam ② Effective ceiling height : 2.4m ∼ 2.7m(국내) 3m(PT.KE) ③ 1st floor height : Reference floor height + (0.3m∼0.4m)

a

a

* Explanatory notes a: Effective zenith height b: Zenith frame and lighting installation (100mm) c: Duct height d: Duct heat insulation covering height (50mm) f: Girder height B: Ceiling height H: Eave height (= A + B)

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Chapter 11 Civil and Building Works

3.2

Building structural planning 3.2.1 General (1) This section covers the design criteria for structural steel and reinforced concrete works, and provides guidelines for the design of steel structures for various production units and auxiliary units. The design shall provide for the appropriate conditions of loading, stresses, deflection and stability requirements, effect of both static and dynamic loads, effect of weather, provisions for thermal expansion, natural lighting and ventilation, roof drainage system etc. The design shall also cater to repair and service facilities with access for maintenance of cranes, cladding and other services. Moreover, the design shall take into account facilities for fabrication, transportation, storage, erection, maintenance and construction. The objective of the design shall be function, service, economy and safety. (2) The design criteria for civil and architecture works shall be in accordance with “Civil & Architectural Design Criteria” approved by the KRI –Indonesia. (3) The design calculations for all the buildings and foundations including cellars, basements, water retaining structures, furnace foundations, tunnels, miscellaneous structures, all equipment foundations etc need to be submitted along with general arrangement drawing. The design calculations shall include static design calculations for all structures and foundations, dynamic analysis for all important structures and foundation subjected to impact, vibrations etc induced by equipment and other external forces, aerodynamic analysis for tall slender structures such as chimneys, towers etc. (4) Building data sheets are to be showing specifications of materials, design standards followed, load data assumed including the loading on roof, walkways, different floors, bulk material density, crane and hoist loading, wind and seismic loading, wind thrusts and vibration considerations, deflection etc. Also, type of flooring, roofing and type of construction to be indicated. The loading combinations and other design assumptions made in design are to be furnished. (5) Seismic design of buildings Buildings shall be designed considering safety against earthquake pursuant to regulations governing standards of Indonesia. The design for seismic shall be performed according to the provisions of the related UBC 97 or SNI-03-1726-2002.

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3.2.2 Reinforced Concrete structure design The design method of concrete structures shall be in accordance with “Civil & Architectural Design Criteria” approved by the KRI –Indonesia. 3.2.3 Steel structural design The design method of steel structures shall be in accordance with “Civil & Architectural Design Criteria” approved by the KRI –Indonesia. (1) Steel Property Steel materials shall be of international type(SNI, ASTM, JIS, KS, etc) with an approval of KRI. (2) Loading Conditions Steel structures shall be designed to resist full operating dead and live loads, with appropriate combination of wind and seismic forces and with due allowances for impact, inertia loading, vibration, temperature, etc. While designing structures, the effect of seismic forces and wind loads shall be independently considered and whichever produces the worst effect, shall be considered along with usual load combinations. Loading conditions shall generally conform to “Civil & Architectural Design Criteria” approved by KRI (3) Combination of Loads - As per load combinations given in Civil & Architectural Design Criteria approved by KRI. - Bending moments arising out of eccentricity of loads from roof truss, roof girder, crane girder etc. with respect to centre line of supporting members shall be considered in the design. 3.2.4 Stability and Rigidity - The structures shall be designed for adequate rigidity and stability in all directions. - The transverse and longitudinal framing or bracing system shall be designed to provided rigidity and resistance against wind, seismic forces, tractive forces, buffer forces and surge loads from crane and any other force generated from equipment and forces from technological pipelines, ventilation ducts/structures etc supported on the building. -Each portion of the building between the expansion joints shall be treated as an independent building and care shall be taken to provide rigidity to each such portion.

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3.2.5 Floor Framing - Floor for vibrating machinery of all kinds, together with the supporting framework shall be adequately braced in both the horizontal and vertical planes. -Special consideration shall be made in the design of floors or structures supporting mechanical equipment to minimize vibration and maintain alignment and level.

3.3 Building Finish Planning 3.3.1 Main Building(Not Decided) (1) Finishing materials Galvanized corrugated steel sheets used in roof and walls of production buildings shall be chosen as the product which shall be approved by KRI and all fixing accessories (such as galvanized steel fasteners) shall be in accordance with the corrugation shape of steel. Floor finishing materials : Exposed concrete or liquid resin color coating 2) Exterior wall finishing materials Galvanized Color Pre-coated Steel Corrugated Sheets and Galvanized corrugated steel sheets shall be used in walls. ① Color sheet (??, t=??mm) : Girth spacing 850 mm (refer to the local product) ② Color sheet (??, t=??mm): Girth spacing 1200 mm (refer to the local product) ③ Bottom wall(H=1.0m) : 50t vacuum extruded cement plate, brick and block structure 3) Roof finishing materials Galvanized Color Pre-Coated Corrugated Sheets used in roofs shall be of trapezoidal profile (with galvanized processed steel substrate) 1)

① Color sheet(??, t=??mm) : Used mainly at small plants, and iron and steel plant buildings ② Color sheet(??, t=??mm) : Used mainly at common plant and rolling plant building ③ Color sheet(??, t=??mm) + Poly form 6t : Used mainly at plants vulnerable to condensation, such as cold rolling plants

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Flat plate width

Size

4)

Molding shape

Color sheets and adiabatic material quality Resin satisfying the surrounding environment shall be coated on the base metal of the galvanized steel plate (galvanized coil: G.I. coil). ① Hot deep galvanized steel plate(G.I.Coil) : Material quality characteristics shall be governed by KRI - Thickness : 0.5mm or 0.8mm(Not Decided) ② Silicon polyester resin coating : Used for the wall and the roof of common plant buildings. - Primer coat Paints: Epoxy group primer (Both sides) Dry coat thickness : 5μ Dry temperature : 200℃ - Top coat Paints: Silicon polyester(Both sides) Dry coat thickness : 20μ Dry temperature : 230℃ 











③ P.V.D.F(Poly Vinyl Di-Fluoride) coating : Applied to acid predicting plants

(cold rolling plants, in general) where pickling lines and acid recovery facilities are operated. - Primer coat

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



Paints : special primer(Both sides) Dry coat thickness : 5μ

Dry temperature : 200℃ - Top coat Paints : P.V.D.F Dry coat thickness : 20μ Dry temperature : 230℃ ④ Adiabatic materials(Poly foam) : Used at plants vulnerable to condensation, such as cold rolling plants. 







- Materials : Poly Foam(fire retardant) t=6mm - Heat conductivity : 0.028 kcal/mh℃ - Absorption : 0.07 mg/cm2 - Bonding method : Thermal fusion (200℃) - Characteristics Must feature strong chemical-resistance, heat-resistance(normal temperature:100℃), and weather resistance, and must be nontoxic to human body.

3.3.2 Auxilirary Building (1) External Wall, Internal Partition and Finishes 1) External wall for all ancillary, auxiliary and welfare buildings shall be constructed of either brick masonry or bubble masonry. The thickness of brick masonry walls shall be minimum 150 mm (included plester) and for concrete block masonry walls minimum 190 mm (included plester). Design of masonry walls shall conform to ASTM C90 Hollow Load-Bearing Concrete Masonry Units

2) Cement sand mortar mix shall be 1.5 for external walls having minimum thickness of 150 mm and also for brick work in protection walls to waterproofing coating in tunnels, basements. 3) All brick and concrete block masonry walls shall be plastered on both sides. Thickness of plaster shall be minimum 20 mm for external surfaces and 15 mm for internal surfaces of walls. Thickness of plaster for ceiling shall be minimum 10 mm.(Not Decided)

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(2)

Floors In general, all floors on ground except in areas like offices and toilets, shall be made of minimum K250(Cubic Stength) reinforced concrete of 150 mm minimum thickness. However, for the production buildings, the design of floor shall also take into consideration technological requirements, imposed loading and other service conditions etc.

3.4 Painting (1) Painting shall conform to General Specification for Painting ( refer to Part 5, ISZ-1 ). (2) Painting of steel structures shall be painted according to the provisions of Paragraph 4.7 Painting, 4.0 Fabrication of steel structures. (3) Painting on concrete and mortar sections 1) Synthetic resin emulsion paint( KS M 5310-external use, KS M 5320-internam use) : Used to finish the concrete and cement mortar section of the interior and exterior wall of buildings. 2) 2-liquid type epoxy enamel paint : As the product features high water-resistance,

(4)

pollution-resistance, and chemical-resistance, this is used to provide waterproof effects by painting the cement mortar section of the basement, waste-water treatment tank, water tank, and septic tanks. 3) Coating type flooring paint 1) This type of paint is used for machine room, laboratory, plant floor, parking lots, and warehouses. 2) This paint shall not be peeled off the painted body, and shall carry high abrasion-resistance, durability, high penetration, acid resistance, alkali resistance, and water resistance. 3) materials and work : One initial coat and one setting coat of acrylic resin floor coating Wood painting 1) Pre-mixed paint( KS M 5312) : Used to protect and color finish wooden part of the interior and exterior part of buildings(door frame, door panels, floor, and wooden wall) 2) Varnish(KS M 5603-Spa Varnish, KS M 5601-Alkyd Varnish): Used to retain

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luster of the interior and exterior part of buildings (door frame, door panels, floor, and wooden wall) while maintaining the original quality of wood. (5)

Special painting (1) In laboratories there is a chance of acid spillage and fumes, the doors and windows shall be painted with acid resistant paint of approved quality and color, and acid-resistant and heat-resistant Paint : Provisions of Paragraph 4.7 Painting, 4.0 Fabrication of steel structures shall apply. (2) Fireproof paint(Not Decided) 2 1) Used on the plant with floor area greater than 2000m , and on major steel structure member of the dangerous materials storage and treatment facilities requiring fireproof structure. For more details on the fireproof structure, refer to the provisions of Article 40, fireproof structure and fire wall, Chapter 5, building structure and materials, Building Code. 2) The fireproof paint shall be of the type which has been designated as fireproof material pursuant to the provisions of the fireproof structure designation and management standards established by the National Construction Laboratory. The fireproof performance of the materials shall not be deteriorated due to water, high heat, chemicals, gas and other toxic materials.

3. 5

DOORS AND WINDOWS All doors and windows of the plant shall be installed in sizes which shall not interfere with the movement of equipment, products or vehicles. If required by law, fire doors shall be installed in the fire zone and/or the opening of fire walls. (1) In principle, the doors and windows shall be made of steel which has undergone the process of powdered electrostatic painting. Part of some auxiliary buildings may use aluminum windows or synthetic resin doors/windows. (2) Types of doors and windows shall be selected based on the equipment characteristics and field situation. - Doors : Sandwich panel hanger door, steel angle door, steel shutter, steel flush door - Windows : Steel window, steel louver, steel window/louver

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SNI: (S-06-1990-F-DPU )

..

Timber paneled glazed door Shutters

SNI: (S-06-1990-F-DPU)

..

ASTM B221 M

..

Timber paneled glazing windows and ventilation shutters Aluminium doors, windows and ventilators

(2) Standard types of doors and windows shall be used to the extent possible. The doors and windows shall be of approved make, quality and colour. Non-standard doors and windows will be used only where there is a specific requirement for such doors and windows. (3) Doors in Production Buildings 1) 2)

Glass for doors shall be minimum 5mm clear glass. Glass for windows shall be minimum 4 mm thick clear glass.

3.6 Ventilation and dust collection (1)

Ventilation In principle, the plant ventilation shall be of natural ventilation system. If unavoidable due to the characteristics of equipment, ventilation may be of combination of natural ventilation and forced ventilation, or forced ventilation alone. (1) Plant building natural ventilation – Ventilation shall be induced based on wind pressure and the internal and external temperature difference. 1) Air inlet(wall) : Air inlets, doors and windows, and other openings 2) Air outlet(roof) : Monitor, gravity type ventilator 3) Monitor discharge temperature : 55℃ 4) Allowable indoor temperature : 40℃ (2) Plant building forced ventilation : Ventilation induced by motive power 1) Air inflow : Forced duct system 2) Air outflow : Powered ventilator (3) Ventilation systems satisfying standards (less than tolerance) shall be installed after checking various conditions such as the indoor caloric value, steam production, gas (fume) production, dust generation, and degree of combustion based on the characteristics of each plant. Allowable limit of pollutants shall be governed by the provisions of 4.1

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Allowable limit of pollutants, Part 2 Design conditions, ISZ-1. (2)

Dust prevention Buildings where products, and electric systems should be maintained free of dust shall be designed to control dust by installing fixed doors and/or windows, windshields and other airtight construction systems.

3.6 Prevention of condensation For buildings where products, equipment or machines may be damaged due to condensation, an effective countermeasure shall be taken. 결로로 인해 제품,설비 또는 기계에 손상이 갈 위험이 있는 건물에서는이를 방지하기 위해 효과적인 조치가 취해져야 한다.

(1) Main plant building roof Color sheets produced by fusing 6T poly foam to the bottom of the color sheet shall be used as the roof materials. (2) Auxiliary building roof and wall Appropriate ventilation systems and heat-insulating panels shall be constructed. 3.7 Soundproofing Appropriate soundproof system shall be designed so that noise level can satisfy the noise tolerance prescribed by the Environment Standards Act. 3.8 Heat resistance Thermal insulation coating (Heat-resistant and fireproof paint) or heat shields shall be installed in places exposed to strong heat, or in areas where structures, equipment and workers are affected by heat. If it is necessary to protect structures and facilities from strong heat, rock wool spray, castable, and/or steel plate may be used as the heat sink materials. 3.9

Fire fighting Anti-disaster and fire-fighting equipment shall be installed in applicable areas pursuant to the provisions of Fire Service Law.

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3.10 Waterproofing and roof drainage (1) Waterproofing (1) To protect products or machines from rain, an effective waterproofing measure shall be taken. (2) Underground structure waterproofing The floor slope shall be 1/100 or more, and trench and sump pit shall be installed for pumping. Construction Joint : Urethane waterproofing (Non-exposed type, T=3mm, B=30mm) 2) Expansion joint : Sheet waterproofing (Primer + Sheet + Bid + Foaming Polyethylene adiabatic materials) 3) Structures penetrating or buried steel structures : water stop plate or water expansion stop materials 4) Water tank, and water treatment tanks : Epoxy waterproofing (3) R.C building roof waterproofing 1) Common buildings such as sub centers : Sheet waterproofing or elastic 1)

inorganic coating waterproofing 2) Buildings where water is drained naturally by the direct grade (pump room, machine room, and electricity room): Elastic inorganic film waterproofing (Coating thickness: 3mm) (4) Steel structure wall and roof waterproofing Main building and auxiliary building : Metallic waterproofing and caulking for waterproofing according to standards (5) Bath rooms and toilets All plant convenience facilities : Cement liquid waterproofing 1) Bath rooms : Overall floor and wall 2) Toilets : Overall floor and wall up to 1.2m (2) Roof Drainage (1) Rainwater shall not overflow or leak through the plant building. The size of gutters, downspouts, and horizontal pipes shall be calculated properly to allow the rain run-off to be within tolerance. (2) The horizontal pipe used for valley gutters shall not interfere with other

facilities. (3) The slope of eave gutters and horizontal pipe shall be greater than 1/150

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3.12 Safety facilities Safety shall be considered above all when designing, constructing and operating plants. All safety facilities shall be designed with enough strength to bear load according to Part 13 Safety Facilities, ISZ-2.

3.13Lighting (1) Plant building natural lighting and lighting system standards (1) Day lighting : Natural lighting + Local lighting (2) Night lighting : Overall lighting + Local lighting combined (3) Natural lighting system 1) Lateral natural lighting : General metal doors and windows, and/or FRP sheet & Polycarbonate sheet 2) Natural lighting from roof : Monitor type, corrugated type, and ridge (ceiling) type (2) Auxiliary building lighting For auxiliary buildings such as the electricity room, machine room, instrumentation room, operation room, and resting rooms, natural lighting and/or artificial lighting systems shall be planned so that workers can enjoy comfortable working conditions.(The light shall be designed not to hinder operators’ work because of light brightness) (3) Luminosity standards shall be governed by the provisions of 7.1.3 Luminosity, 7.0 Construction Standards, Chapter 7 Electric Equipment.

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4.0 Fabrication of steel frame 4.1 General 4.1.1 The size of the steel structure member to be fabricated at plant shall be decided taking into consideration whether the structure can be fabricated at site, transporting means and path. 4.1.2 The manufacture weight, when the steel frame weight is calculated, shall be computed based on design documents. The steel frame weight shown on the estimation sheet and specifications is a net weight which does not include the weight of bolts and welding rods. 4.1.3 The range of steel structure fabrication at plant and site shall be decided according to design drawings. 4.1.4 Documents to be submitted to KRI for approval after signing contract are as follows. Any other documents not shown in the following table but requested by KRI shall be submitted separately. Document 1. Fabrication process plan 2. Monthly process report 3. Shop drawings and assembly drawings 4. Shipping plan and packing list 5. Inspection and test plan(ITP) 6. List of manufacture weight 7. Other documents 8. Material inspection results 9. Steel structure fabrication records

Submission date - One month prior to starting work - Within 5 days of the following month - Immediately upon completion - One month prior to shipment - One month prior to starting fabrication

Form Specified form 〃

- Upon completion of works - As needed - At each delivery

〃

- Upon completion of delivery

〃(A3x3 copies) Specified form 〃

〃 〃(A3x3 copies) 〃

Remarks Including organization chart

Ocean shipment portion Materials and manufacturing process inspection Packing and products shipment inspection Statement of completed quantities to be submitted. Inspection reports Non-destructive inspection, photos showing each process or work As-built drawings

4.2 Materials 4.2.1 Steel, bolts/nuts, and welding materials used to fabricate steel structures shall be equal to those shown on design drawings, or other equivalent standards (JIS, DIN, ASTM, AWS). Materials shall be subject to prior confirmation of KRI -Indonesia. 4.2.2 To facilitate discrimination of steel products, materials of the same profiles (material quality and thickness of steel plate, or the profile of the section in the case of shape steel) having different standards and quality shall be discriminated by symbols or colors. 4.3 Preparation of shop drawings and full-size drawings

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4.3.1 Shop drawings act as a guideline in place of design drawings regarding fabrication and installation, and shall contain the following items. (1) Steel floor system diagram, block diagrams, and list of members. (2) Detailed profiles and sizes of steel member, member symbols, product quantities, product symbol, and materials quality. (3) Profiles and sizes of welded and high-power bolt joints, coupling symbols, type and grade of bolts. (4) Equipment annex steel products, steel bar through holes, temporary steel structures, and fasteners. 4.3.2 This drawing shows accurate sizes, shape and quantities of the members required for the fabrication of steel frame. Standard drawings, detailed drawings and assembly drawings relating to the shop drawings shall be submitted to KRI for prior approval. (1) Types shop drawings and scales ① Standard drawings(1/100 – 1/200): Show the standard size of buildings (column intervals, floor heights, etc.), standards of joints, and interference relation with other works. ② Structural drawings (1/100 – 1/200) ③ Detailed drawings(1/10 – 1/30, none scale): Show connections and quantities of columns , beams, shapes and sizes of members, hole position, and gusset plate. ④ Assembly drawings : These drawings, used for fabrication, show steel structure attachment used to erect steel structures at site, and member numbers for each shipment unit according to the work process. The drawings shall be prepared free of errors for the erection of steel structures. 4.3.3 The full-size drawings shall be prepared by indicating the standards of member cutting, drilling, machining, and assembling in regular sizes based on shop drawings. The hole position, gusset plate, and stiffener shall be fabricated by copying models from the full-size drawings. 4.4 Machining 4.4.1

Marking-off (1) If materials are deformed, the affected part shall be corrected appropriately. Templates and other tools shall then be used to mark the necessary areas accurately. The templates shall not be used for more than 20 times. (2) The external face of the high-strength steel(SM490 or more) and the bent soft steel shall not have any traces of file, drills, or punch. (3) The size of marking-off shall be appropriately selected in consideration of contraction, and/or strain occurring during the course of fabrication, and finishing.

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4.4.2

Cutting (1) Unless specified otherwise in drawings, the cut section shall be perpendicular to the axial line. (2) Manual cutting shall be carried out only for a minor part. (3) If there are any traces of saw, cutting, waveform and slag attached, a grinder shall be used to remove them. (4) The unit size of steel shall be decided taking into account the contracted strain occurring during the process of machining and the finishing work. (5) The accuracy of the gas pipe cut section shall be below 200S, with the notch depth less than 1mm.

4.4.3

Bending (1) Bending is classified into cold bending and thermal bending. In the case of thermal bending, work is carried out under red heat condition (800 - 900°C), but shall not be worked under blue shortness area (200∼400°C). In such case, temperature conditions shall be as follows: (However, water-cooling start temperature shall be 650°C and below.) ① If air-cooled after heating: 850°C∼900°C ② If water-cooled immediately after heating: 600°C∼650°C 850°C∼900°C ③ If water-cooled after air-cooling: The internal bending radius of cold bending are as follows: Members

Internal bending radius

Members requiring plastic strain capability, such as the haunch of columns, beams and bracings.

Minimum 4t

Members other than the above.

Minimum 2t

4.4.4

Remarks

r : Internal bending radius t : Plate thickness

Drilling (1) Welded part shall be drilled upon completion of welding. If prior drilling is required due to the welding shrinkage occurring during the welding process, drilling may be carried out prior to welding. (2) Plate measuring less than 9㎜ in thickness shall be drilled with a punching machine, or with a drilling machine if the thickness is greater. (3) Drilling for high-strength bolts shall be carried out by a drilling machine. If the connected part is to be blasted, drilling shall be carried out prior to blasting.

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(4) Hoes for bolts, anchor bolts, and steel bar shall be drilled with a drilling machine.

If the cut section has slips or dragging resulting in the loss of perpendicularity, such defects shall be corrected with a grinder. 4.4.5 Beveling (1) Beveling of the welded part shall be performed with a gas cutter as a principle. (2) The roughness and notch level of the beveled surface shall be as follows. If the condition exceeds tolerance, use build-up welding, grinders or other appropriate method to supplement shortcomings.

4.4.6

Roughness

Not exceeding 100S

Notch depth

Not exceeding 1.5mm

Friction face treatment (1) The friction face of the high-tensile bolts shall carry coefficient of sliding greater than 0.45. (2) Rust, black film, dust, oil, paints and welding spatter shall be removed from the friction face and the part which makes contact with the washer. (3) Mill scale shall be removed from the base metal by using a plane grinder covering the area surrounding the hole within a range 2 or more times the washer diameter. In the case of splice plate, a wire brush shall be used to remove scale from the entire area. (4) The friction face shall not have any uneven place, such as the cramp traces. (5) If a splice plate is temporarily fixed to the member, oil-free fitting-up bolts shall be used. (6) If the area surrounding the bolt hole is trimmed with a grinder after blasting, the area shall be left with red rust. Burr and strain generated during punching must be removed. (7) Appropriate protective device shall be provided prior to painting the friction face.

4.5 Welding 4.5.1

General (1) All welding process specifications(WPS) shall be prepared by the supplier and submitted to KRI for approval. (2) Profiles of welded part The welded part shall be free of any harmful defects which might damage the performance of joints due to cracks, penetration defects, ingress of slag, blow hole, and under-cut. (3) Current, voltage and other factors Welding shall be performed under the supervision of welding engineers. For an effective welding, appropriate welding current, arc voltage, welding speed, gas discharge, and temperature between passes shall be selected and applied. (4) Preheating 1) If preheating is required, the preheating temperature shall be selected based on the following factors:

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① ② ③ ④ ⑤

Steel product (SM 400) (SS 400) SNI shall be applied

(SM 490) SNI material shall be applied

Chemical component of steel Degree of restrain at joints Welding heat input Steel plate thickness Steel temperature Preheating is carried out in case temperature is low, the degree of restrain is high, material is thick steel plate or contains large carbon contents. Preheating temperature

Conditions A. If the temperature at job site is 5℃ or less; B. If the degree of restrain is large; or C. If the plate thickness is 25mm or more. A. If the temperature at job site is 5℃ or less; B. If the degree of restrain is large; or C. If the plate thickness is 25mm (19mm) or more, but less than 38mm. If the plate thickness is 38mm or more

50℃ or more

50℃ or more

100℃ or more

Remarks - For regular welding and tack welding - For regular welding and tack welding. Figure in ( ) is for tack welding. - For regular welding and tack welding

(5) End tab 1) If the base metal has beveling on both ends, end tabs shall be attached to the

ends so that the shear plane can be welded satisfactorily. The end tab shall be at least 25mm long. However, other methods may be used if approved by KRI. 2) If end tabs are installed on the joints of the columns and beams, backing shall be attached, but tack welding shall not be performed directly on the base metal. Tack welding may be performed within the beveling if it is required to re-fuse the tack weld. 3) End tab need not be cut. If cutting is needed, proper care shall be exercised not to damage base metal. 4.5.2 Welding technician (1) Chief engineer shall always stay at the work site, and the engineer who directly supervises welding shall stay at the welding site at all times. Prior to dispatching the chief engineer and the supervisor engineer, their qualifications shall be submitted to KRI for approval. (2) Welders shall be those who possess licenses issued by approved institutions, or those who have passed the technician examinations.

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(3) If it deemed necessary by KRI because the qualifications of the welder are

questionable, the welder shall undergo appropriate qualification test. 4.5.3 Selection of welding methods (1) Welding methods shall be as shown on design drawings. (2) If special welding methods, other than those specified in the design documents, are used, the contractor shall perform trial welding to obtain KRI’s approval. (3) Gas welding may be applied when the material thickness is 2.3mm – 4mm. 4.5.4

Selection of welding materials (1) Welding machines with sufficient performance and capacity shall be used according to the types of welding rod and welding materials. (2) The type of welding rod shall be selected according to the profiles of welding joints, materials quality and welding posture, and based on welding current value. (3) Welding materials such as the covered arc welding rod, wire, flux and gas shall be selected from among those specified in SNI standards (SNI 03-1729-2002), ANSI/AWS D1-1, International standards satisfying the type of steel, joint type, beveling profiles, and welding methods.

4.5.5 Selection of welded joints (1) General 1) Welded joints shall be selected taking into consideration the welded part structures and plate thickness, types of load, welding method, and strength. 2) Welded joints shall not be designed to be concentrated in 1 place or to be near to each other. 3) As much as possible, weld lines shall be so designed to prevent crossing with each other. If the lines cross under an unavoidable situation, scallops shall be designed. 4) Accuracy of the welded joints shall be governed by the provisions KRI’s steel structure inspection standards (PN-S-05-17). (2) Butt welding 1) Unless specifically instructed otherwise, butt welding shall have minimum

2) 3)

4) 5)

reinforcing strap. The height of the strap shall be 3mm or less in manual welding, and 4mm or less in the automatic or semiautomatic submerged arc welding. The strap shall not undergo finishing process unless it creates interference with the fabrication and installation work. If welding is done from both sides, back shall be chipped prior to welding. Arc gouging or air brush shall be used for the back chipping, and its depth shall be to the level where the melted metal appears after the bead is removed. If satisfactory penetration is achieved through automatic submerged arc welding, no back chipping shall be carried out. If welding is done from the groove side through the use of a backing strip, root intervals and beveling angles shall be checked to ensure satisfactory penetration to the backing strip, paying particular attention to the to the

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primary welding. 6) I the height of the base metal surface is uneven in the butt welding, the surface shall be baked in a grade of 1/5. No baking is required in case the difference in the surface height is 4mm or less in the manual and semi-automatic welding, and 3mm or less in automatic welding. (3) Fillet welding 1) Fillet welding shall be carried out with the member adhered as close as possible. 2) There shall be no severe difference in angles of the equiangular fillet welding. 3) The interval of intermittent welding shall be the length derived by adding the value greater than 2 items the fillet size to the effective size. 4) The height of the fillet reinforcing strap shall be 0.1 S±1㎜(S, here, is the designated size.) or less. (4) Edge welding Two or more base metals are overlapped almost in parallel and the section of the base metal is welded, with the throat depth being in parallel with the base metal. (5) Tack welding 1) Tack treatment ① Water, paints, and oils attached to the beveling shall be removed through heating by gas. ② A grinder or wire brush shall be used to remove rust from the beveling. ③ Mill scale wash primer or a grinder shall be used to remove foreign matter from the beveling of automatic welding. 2) Tack welding rules ① If welding lines cross each other, tack welding shall be performed at least 150mm away from each crossing. ② In the case of filling welding, tack welding shall be performed on the regular welding position. ③ Tack welding shall be carried out on the edge of member, solid angle part, and the regular welding part, avoiding places where machining or strength might be adversely affected. 3) The minimum length of the tack shall be as shown below. In principle, the tack intervals shall be approximately 15~30 times the plate thickness. Material thickness(mm)

Minimum length(mm)

Less than 3.2

30 or more

Less than 3.2 –25

40 or more

25 or more

50 or more

4.6 Temporary fabrication 4.6.1 Prior to painting, the steel structure fabricator shall temporarily assemble each part to verify sizes are accurate, or to make necessary correction if necessary. The range of

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Chapter 11 Civil and Building Works

temporary fabrication shall be governed by the special specifications or drawings. 4.6.2 Temporary fabrication shall be carried out at the request KRI. Manufacturers of the member (crane girders, columns, truss, etc.) which are separated into one or more pieces due to the characteristics of the member, such as when transporting long and large materials, and the hoppers, shall carry out temporary fabrication in the presence of KRI. Any defects found on member shall be corrected and supplemented. 4.7 Painting 4.7.1 General pertaining to painting shall be governed by the provisions of Paragraph 2, Painting, Part 5 Paintingcoloringpacking, ISZ-1. 4.7.2

Preparation of surface (1) Every oil, grease, drips, mill, rust, corrosions, oxides and other foreign matters shall be removed from surface prior to beginning painting. (2) Use solvent to remove oil or grease.

4.7.3 Characteristics of paints (1) Paints used for this project shall be domestic SNI standard products or equivalent quality products. (2) Different colors shall be used to distinguish primer coat, under coat and top coat. (3) paint quality 1) Pre-mixed paint ① Epoxy primer (Shop primer) This primer, used to as metal pre-treatment agent to prevent rust or corrosion, is applied immediately after shot blasting based on the following paint specifications. Method of mixing with thinner and the degree of agitation shall be decided after discussion with the paint maker, and shall be used after obtaining approval form KRI. - Component : Epoxy 2-liquid type paints (with superior rust resistance, water-resistance, sea-water resistance and chemical-resistance) - Dry film thickness : 35μ/1 coat - No. of Painting : 1 time(spray) - Interval of re-painting : 24 hr or more ② Oil paint : KSM 5312 class 1 - Component : Long oil alkyd resin paints - Dry film thickness : 70μ/2 coats - No. of Painting : 2 times (spray) 2)

Acid-resistant paints The following types of paint shall be used in areas where acid and gas are generated. Method of coloring, mixing with thinner, and the degree of

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Chapter 11 Civil and Building Works

3)

agitation shall be decided after prior discussion with the paint maker, and shall be used after obtaining approval form KRI. ① Zinc dust paints : (For primer coat) - Component : Inorganic silicic acid zinc pre-treatment primer (Chemical resistant, thermal resistant, and anti-corrosive primer) - Dry film thickness 60μ - No. of painting: 1 time (spray) - Interval of re-painting : 24 hours ② Epoxy resin paints ( for under coat): - Component: 2-liquid type epoxy polyamide (Paints featuring abrasion resistance, acid resistance, and sea-water resistance) - Dry film thickness : 40μ - No. of painting: 1 time (spray) - Interval of re-painting : 8 hours ③ Epoxy enamel paints (For top coat) - Component: 2-liquid type epoxy polyamide enamel paint (Paints featuring abrasion resistance, chemical resistance, and anti-corrosiveness) - Dry film thickness: 80μ(40μ/1 time) - No. of painting: 2 times (spray) - Interval of re-painting : 8 hours ④ Selection and management tests for the above paints shall be conducted based on KS standards. Heat-resistant paints ① Primer coat - Component : Self-hardening inorganic silicic acid paints - Dry film thickness : 75μ - Number of painting : 1 time (spray) - Drying time and interval of re-painting

Item

5℃

20℃

30℃

40℃

Tack free time

60min.

30min.

10min.

5min.

Semi-hardened

3hrs

2 hrs

1 hr

45 min.

Minimum Maximum

48hrs 6 months

24 hrs 6 months

12 hrs 6 months

8 hrs 6 months

② For top coat

-

Component : Silicon group paints with superior heat-resistance - Dry film thickness : 50μ(25μ/1 time) Number of painting : 2 times(spray) Drying time(25℃) : Tack free time – 20 minutes, hardening time - 150℃ x 30 minutes

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Chapter 11 Civil and Building Works

4.7.4

Interval of re-painting (25℃) : 4 hours or more

Painting requirements (1) Areas not to be painted 1) Friction surface of high-strength bolts 2) Parts which are attached to, or buried in, concrete 3) Crane Rail 4) Contact part of pin roller 5) Parts which are to be welded at site, and the areas within 100mm from the surrounding area of machines shall not be painted.

4.7.5 Drying and others (1) Painted maintenance shall be left in a clean area for 48 or more hours for drying. (2) Paint coat which has been damaged during transportation shall be re-painted at site prior to erection. 4.8 Packing 4.8.1

General concerning packing shall be governed by the provisions of Paragraph 4.0 Packing, Part 5 Painting coloring packing, ISZ-1.

4.8.2

Steel member packing method (1) Column In general, column members are shipped without packing. However, weak parts like the protruding gusset plates, or the I-beam edges shall be protected with appropriate dunnage. Members that can be tied together, such as channels, shall be packed according to general regulations. (2) Main rafter and monitor roof Web members measuring less than 2m which are not assembled prior to shipping shall be tied together with steel wire or tie hoops by type and placed in a crate equipped with openings. Main members shall be tied prior to shipping. (3) Sub-truss, tie beam and bracing Sub-truss, tie beam, and partially assembled bracing shall be tied together by similar width and shapes. (4) Crane girder Crane girders shall be reinforced by dunnage on both ends at an interval of 3 m in the direction of the stiffener to withstand lateral load, and tied with tie hoops. In such case, the suspending string shall match with the position of the stiffener. If bolts can be used in lieu of flat bar, bolts measuring 1/2” or more in diameter can be used as the fixed stiffener. (5) Bracings (Purlin & furring strip) I-beams measuring 2m or more in length and angles shall be tied together. Those measuring less than 2m shall be tied together with tie hoops prior to packing. Stairs that can be stacked shall be tied together; and those that cannot be stacked shall be loaded piece by piece after providing appropriate reinforcing and protective devices. (6) Gusset plate Gusset plates with uniform size shall be firmly clamped with bolts measuring 5/8” or more in diameter (15mm) for loading purpose, and shall be packed in crates provided

11-41

Chapter 11 Civil and Building Works

with openings at top. Gussets plates measuring 0.5㎡ shall be inserted between square dunnages, and clamped firmly with bolts measuring 5/8” or more in diameter (15mm) for loading. (7) Light gauge steel Light gauge steel shall be protected by dunnage at the edge for shipment. The center part of the steel shall be tied with #8 steel wire at an interval of 2m. 4.9 Fabrication inspection and test standards Quality control inspections shall be classified into materials inspection, shop drawing and full-size drawing inspection, processing inspection, welding inspection, finished product inspection, Painting and packing inspection, and pre-shipment inspection. Inspections shall be divided into a supplier inspection and the KRI-attended inspection. KRI may commission a 3rd testing institution to carry out an attended inspection. General related to the fabrication inspection shall be governed by the provisions of Paragraph 2.3 Procurement, Part 3 Engineering, ISZ-1. For more details, the KRI’s steel structure fabrication inspection standards (PN-S-05-17) shall be referred to. 4.9.1 Inspection process (1) The supplier shall begin fabrication and in-process inspection according to its own process schedule upon receipt of shop drawings. For items that require an attended inspection, the supplier shall submit a request for attendance 5 days prior to conducting inspection. (2) Inspection procedures and items pertaining to fabrication process shall be governed by the provisions of KRI fabrication and inspection standards. 4.9.2

Material inspection (1) Applicable standards The supplier shall examine the mill sheets issued by material makers, and if the products provided by the makers do not satisfy the requirements of KRI, a separate materials inspection shall be conducted. (2) Destructive inspection This is a type of a materials inspection carried out by destroying the test piece or by applying strain to the materials. 1) Strength test : tension, compression, bending and warp test 2) Impact test : Izod and charpy impact test 3) Hardness test : Brinell, rockwell, Vickers and shore hardness test (3) Non-destructive inspection This type of test is conducted to check the properties of the finished products without destroying casting, forging, welded materials and mechanical parts. Available tests include RT (Radiographic Test), UT (Ultrasonic Test), MT (Magnetic particle Test), and PT (Liquid Penetrant Test). (4) Sampling standards, testing methods, and the judgment criteria shall be decided based on KRI standards or other equivalent regulations.

4.9.3 Shop drawings and full-size drawing inspection (1) Shop drawing inspection

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Chapter 11 Civil and Building Works

The supplier shall obtain approval of KRI on working drawings prior to starting actual work. Any discrepancies noted during examination shall be corrected for approval prior to preparing the full-size drawings. 1) Types and scale of shop drawings shall be checked. 2) The quality and size of members, sizes of the roof, and whether members can be erected shall be examined. 3) Quality, size, length and the pitch of bolts shall be inspected. 4) Welded profile, welding places, and welding methods shall be examined. (2) Full-size drawing inspection Full-size drawing inspection shall be conducted covering all processes according to building sizes and work process. 1) The original size shall be inspected, and any error shall be within 1mm. 2) Working points of the member joints shall be checked. 3) Position and size of each member, sizes of each side from the column center, and the size from the beam top to the bottom shall be checked. (Stiffeners, tie plates, base plates, etc.) 4) Clearance of each part 5) Anchor bolt position, pitch gauge, and bolt diameter shall be examined. 4.9.4

Workmanship inspection Prior to performing regular welding, cut state of shape steels and plates, finishing status, strain, sizes and cambers shall be checked, and make correction if needed prior to temporary fabrication.

4.9.5

Welded part inspection Welded part inspection shall be divided into fabrication inspection and confirmation inspection. The fabrication inspection shall be carried out by the maker to satisfy all requirements of the contract and specifications, and is classified into before-assembly, during-assembly, during-welding, and post-welding inspections. The confirmation inspection shall be conducted by KRI whenever deemed necessary. (1) Visual inspection All welding parts shall be checked visually. If the results satisfy the standards of KRI’s steel structure fabrication and visual inspection (PS-N-05-17), the welding job shall be considered accepted. (2) Non-destructive inspection For details of non-destructive inspection, KRI’s Non-destructive inspection standards (PN-S-05-36) shall be complied with. For major structural members of buildings, the following standards shall be followed. 1) Ultrasonic Test (U.T) 100% test shall be conducted for the part which is marked as Full Penetration on drawings, among the following major welded parts. ① Main Column - Welded part of the low column and upper column joint (A) - Top and bottom welded flange of the bracket used to connect columns and truss (B)

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Chapter 11 Civil and Building Works

② Crane girder

Joints of the top and bottom flange and end plate(C) ③ Main truss The top and bottom welded flange of the joint of the central truss member (F) 2) Radiographic Test (R.T) 100% test shall be conducted for the part which is marked as Full Penetration on drawings, among the following major welded parts. ① Main column Butt joint welded part of flange(D) ② Crane girder Butt joint welded part of flange and web(E) ③ Non-destructive inspection judgment criteria for welded part - Welding status is considered accepted if the test result is KRI inspection standard’s level class 2 or higher level - If the non-destructive test results in rejection, 2 multiples of the defective areas shall be tested additionally at the expenses of the contractor.

4.9.6 Finished product inspection (1) Members manufactured at plants shall be sell-inspected, and the related records shall be submitted to KRI if requested. Any difference in size found during the steel structure accuracy test between the specified size and the actual measured size shall be recorded on the test report. (2) Products size standards This is an inspected conducted to check the size accuracy of the manufactured steel structures and the finishing status of products. Inspect reports shall be prepared for approval by the supervisor and inspector. Product tolerance, inspection items, and inspection methods shall be governed by the provisions of KRI’s steel structure inspection standards.

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Chapter 11 Civil and Building Works

4.9.7

Painting inspection Painting inspection shall be conducted according to KRI’s Painting and Packing inspection standards (PN-S-05-35).

4.9.8 Packing and pre-shipment inspection (1) Packing inspection shall be carried out according to the provisions of Paragraph 4.8 Packing, and KRI’s Painting and Packing Inspection Standards. (2) Attended pre-shipment inspection shall be conducted following the supplier inspection. (3) Quantity of the products actually shipped shall be checked against that shown on shipping documents.

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Chapter 12 Refractories

Chapter 12 Refractories

12-1

Chapter 12 Refractories

Table of Contents 1.0

Scope of application ................................................................................................

3

2.0

Design criteria ........................................................................................................

3

3.0

2.1

General ...............................................................................................................

3

2.2

Definition of terms ........................................................................................

3

2.3

Design criteria .................................................................................................

5

2.4

Design criteria for studs for monolithic refractories .................................

8

Standards for material and material quality ......................................................

9

3.1

4.0

5.0

6.0

Material quality standards for refractories(Shaped & Unshaped) .......

10

Test and inspection standards .............................................................................

12

4.1 General ...............................................................................................................

12

4.2 Inspection types and standards .......................................................................

13

Packing and Marking ............................................................................................

16

5.1 Packing material and method ........................................................................

16

5.2 Marking ...............................................................................................................

16

Others .......................................................................................................................

16

12-2

Chapter 12 Refractories

1.0 Scope of application This standard is applicable to the general technical specifications used to purchase refractories for POSCO-Indonesia, or used as the design and inspection standards for the refractories carried out by the supplier at the request of POSCO- Indonesia. 2.0 Design criteria 2.1 General This standard is applicable to technical examination, basic engineering and detail design carried out to determine the refractory material quality, profiles and structure by POSCO- Indonesia or the supplier. 2.2 Definition of terms In order of progress of engineering the terms as mentioned shall be changed as follows: Basic Data (BD) Basic Engineering (BE) Detail Engineering (DE) The information/data and their nature to be furnished under each of the above mentioned categories shall be as follows:

2.2.1 Basic data includes global functional information for commencement of work such as for an estimate (indicative) outlining the quantities, broad specifications, tonnages etc. These data should be based on similar work undertaken by a designer. 2.2.2 Basic engineering covers data outlining the actual operational and target ed expectation in respect of performance of an equipment or system such as operating temperature, pressure, atmosphere, dimensions of equipment in the form of arrangement drawings with or without lining work , ambient conditions, material specification etc. 2.2.3 Detail engineering shall be on the basis of basic engineering data and shall include information/data as mentioned below: 1) General arrangement showing thickness of refractory lining according to specifications, expansion joint, detailed specification of refractory materials (data sheet), anchor details (quantity, dimensions, spacing etc.)

12-3

Chapter 12 Refractories

2) Bill of quantity i.e. no./ton for each shape, size and quality, laying information such as no. of different shapes of bricks in each ring, mortar thickness. The quantities should be both in net and gross to include losses/breakages during erection. 3) Erection document to cover safety, application engineering such as gunning, injecting, pumables, requirement of erection materials such as expansion joint materials, paints, welding instructions including specification for welding rods, recommended procedure for dryup and drying cycle. 2.2.4 Refractories : It resist high-temperature and chemically stabilize nonmetal inorganic material or products It generally represents industrial refractories more than refractoriness SK 26 and is composed shaped and unshaped. Materials is divided Oxide, Carbon, complex non-oxide and non-oxide. 2.2.5 Alkali or Basic Refractories : It plentifully contains Alkali Clay Oxide (MgO,CaO) 2.2.6 Acid Refractories : It generally marked RO2 refractories The chief ingredient of this refractories are Acid oxide like Silica and etc. 2.2.7 Neutral Refractories : It does not belong to Acid and Alkali. There are generally High-Alumina, Carbon, Silicon-Carbide and Chrome refractories 2.2.8 Shaped Refractories : It is general term for firebrick and heat insulated brick. 2.2.9 Insulating Refractories : It is general term for the low conductivity refractories 2.2.10 Unshaped Refractories / Monolitic Refractories : It is general term of fine power or mixed clay refractories. Castable, Plastic, Spray Materials, Patching Materials, Mortar, Gunning Materials, Coating materials etc. 2.2.11 Precasted Block : After unshaped refractories applied to forming, it cure the shaped refractories. In order to avoid trouble when complicated shape refractories works, It increase the usage recently. 2.2.12 Castable Refractories. : Refractories, in which refractory aggregate and alumina cement are mixed, are fine power or aggregate. It has a hydration or chemical bondage, and worked hydraulic-working, ramming and gunning method.

12-4

Chapter 12 Refractories

2.2.13 Plastic Refractories/Moldable Refractories : Unshaped refractories in which refractories aggregate and reversible materials mixed with water, and then made to clay. 2.2.14 Spraying Refractories/Gunning Refractories : Refractories are constructed by spray on the normal or hot temperature. 2.2.15 Patching Material Refractories : Refractories with properties similar to refractory mortar which have controlled grain size so they are easy to use for patching or part repairment. 2.2.16 Mortar Refactories : Materials for bonding bricks in a lining. According to hardening method, It divided three type, Heat-setting, Air-setting and Hydraulic-setting 2.2.17 Coating Refractories : Refractories which laid on by a trowel and sprayed with painting, is improved to coat the cover. 2.2.18 Ceramic Fiber : Man-made fibrous refractory materials. There are blanket, Felt, Mould, Vacuum Form, rope and etc. 2.2.19 Others refractory terminology refer to SNI( ) (Refractory Terminology) of SNI code 2.3 Design criteria 2.3.1

General (1) The designer shall review the mantle drawings applicable refractories, and check the inside furnace temperature, surroundings, required life-time and other operating conditions for reflection in each stage of design. (2) The designer shall select required items from the following for calculation and reflection in design. 1) Temperature distribution on each part of the furnace 2) Temperature of the external mantle 3) Countermeasures for thermal expansion 4) Anchor shape and arrangement 5) Load and other required calculations (3) The standard shapes and sizes of the firebricks shall be governed by the provisions of related Indonesia Standard regulations and other equivalent international standards(ISO). (4) The bricks shall be designed in a stair form so that 2 or more joints will not run straight lengthwise. (5) The wedge type bricks shall be 1/2 or more of the circular size when

12-5

Chapter 12 Refractories

designing the bricks of a ring structure, and the top and bottom shall not be overlapped towards the direction of height. (6) Major considerations for forming a brick structure shall be as mentioned below: 1) The brick shape, particularly when designing the Dome, Arch, or Circle, shall be of simple types which can be formed by pressing. 2) While designing a complicated profiles the following non-standard brick shapes can be used : ① Tongue & groove brick ② Anchor & hanger brick ③ Burner tile ④ Jack arch brick ⑤ Bricks used for heat-insulating work ⑥ Short or round bricks

JACK ARCH

BURNER TILE

TONGUE & GROOVE

ANCHOR BRICK

3) Brick structure standards applicable to inside the cylindrical system

(Fan-shaped bricks) - Correlation exists between R and A; however, this design is applicable when the size of h is 2mm or more in case R is small. - Calculation basis

12-6

Chapter 12 Refractories

rA r+T

a=

(r+T)a a

A=

rA R

=

(inside chord)

Ra r

=

(outside chord)

aT r=

, d = 2r

A-a

RNr== r 2πT + T , D =(Approximately 2R value) A-a πD (2πT) Nr = (Approximately value) A-a to work 1 round. Nr = Number of bricks required A

4) Arch, wedge type brick structure design standards

(Vertical or horizontal bricks) If there is a large difference between A-B, part B becomes easily breakable since assembling parts are inserted during the brick molding. Therefore, the difference shall be 30% of L at maximum. - Calculation basis a=

rA

rA

=

r+T

A=

(inside chord)

R

(r+T)a

Ra

=

a

(outside chord)

r

R = r + T , D = 2R

r=

aT

,

, d = 2r

A-a

Nr =

2πT

(Approximate value)

A-a 2πT Nr =

πD

=

A 12-7

A-a

(Approximate value)

Chapter 12 Refractories

Nr = Number of bricks required to work 1 round.

* Arch and Wedge structure Arch structure: The horizontal brick structure where the fireproof brick is tapered laterally. Wedge structure: The vertical brick structure where the fireproof brick is tapered vertically.

thickness thickness

2.4 Design criteria for studs for monolithics refractories 2.4.1

Selection of studs (1) Studs are used to safely support the refractory materials to the steel wall, and to prevent the refractories from coming off. (2) Lining thickness, number of layers and operating temperature condition shall be taken into consideration prior to selecting studs. In general, the studs shall be buried up to 2/3 of the thickness of the constructed refractory material. (3) Examples of studs selected (Typical for guideline and not binding) ARCH Cylindrical Curved Vertical Type Sloped Wall Double Wall Ceiling Wall Wall

L type STUD Y type STUD Brick

L type STUD Y type STUD

L type STUD Y type STUD V type STUD

Y type STUD HangerBrick

Y type STUD HangerBrick

Y, V type STUD Brick

2.4.2

Stud installation spacing (1) The studs shall be arranged in a grid form or in zigzag form. Studs may be installed by welding or bolting; however, installation of studs shall be designed based on welding method except in a special case. (2) For temperature up to 1200°C metallic anchors are usually installed and above 1200°C ceramic anchors are being used.

2.4.3

The following is the design standards for the y type studs which are used in most cases.

12-8

Chapter 12 Refractories

Unit : mm Furnace Stud wall length Thick(A) ness

Stud width (B)

Stud thickness (C)

Stud spacing based on the condition of the furnace wall

Stud exposed to:

Vertical wall

Sloped wall

Ceiling wall

Load(㎏)

50

33

8

2.3

75

50

45

0.5

100

66

16

2.3

150

100

95

4.5

150

100

25

3.2

175

150

120

9.0

200

135

35

4.5

300

200

170

12.0

Stud profile

3.0 Standards for material and material quality

This materials and quality standards contain common information on uses and types. If different standards are to be applied due to using conditions and/or purposes, decision shall be made after having a discussion with POSCO-Indonesia.

3.1 Material quality standards for Refractories(Shaped & Unshaped)

12-9

Chapter 12 Refractories

Main Usage Component Silica Brick SiO2 Cokes Oven, Hot Stove, etc. Clay Brick SiO2 Blast Furnace, Finex, Al203Sintering Furnace, etc Alumina Brick Al203 Blast Furnace, Sintering Furnace, etc High Alumina Brick Al203 Blast Furnace, Ladle, SiO2 Sintering Furnace, etc Silicon Carbide Brick SiC Blast Furnace, Finex, etc Carbon Brick C Blast Furnace, Finex, etc Alumina Silicon Carbide Al2O3 Hot Metal Ladle, Carbon Brick SiC Torpedo car, Charging C Ladle, etc Alumina Magnesia Al2O3 Teeming ladle, etc Carbon Brick Mg0 C Shaped Alumina Carbon Brick Al2O3 Submerged Nozzle, Refractories C Sliding Nozzle, etc Zircon Brick ZrO2 Ladle, Nozzle, SiO2 Stopper, etc Alumina Zircon Silica Al2O3 CCM Nozzle etc Brick ZrO2 SiO2 Magnesia Brick MgO LF, Degasser, ○ “업무질” 평가척도 (팀원 : 전동식) Sintering Furnace, etc 달성 척도 난 중 평가지표 평가산식 목표 직무 단위업무 Magnesia 이 요 Brick치 MgO상 LF, Ladle, etc (KPI)Carbon (착안점) 중 하 도 도 C 표준서 검 적용성/편의 상 상 평가자평가 100% 이상 100~90% 토 성 Chrome Brick Magnesia MgO Degasser, 90% 미만 평가자 평 수주 지원 상 상 수주지원 상위 30% 중간 50% 하위 20% 가 Cr2O3 Sintering Furnace, POSCO 평가자 평 Al2O3 Teeming Ladle 상 상 수행완성도 상위 30% 중간 50% 하위 20%etc 가 대응 자세 수주 Magnesia Dolomite MgO Converter, 평가자 평 영업 전문 지식 상 상 기술 지식 상위 30% 중간 50% 하위 20% 가 Brick CaO Teeming Ladle, etc 업무 협조시 다 타 분야와 타분야와 업무협 소 업무 협조시 Magnesia Brick MgO Sintering Furnace, 타 분야 원만한 업 의시 적극적으로 극적으로 대응하 소극적으로 대 etc 수행Spinel 상 상 업무협조 무 협조 유 대응하여 적기에 여 응하여 목적달 완성도 Al2O3 지 소기의 목적 달성 목적달성에 다소 성이 어려움 시간이 걸림 Alumina Spinel Brick Al2O3 Teeming Ladle, MgO Sintering Furnace, etc

Classification

Kinds

Remark

-1-

Classification

Kinds

Main Component

12-10

Usage

Remark

Chapter 12 Refractories

Silica mortar Silica injection repair material Clay Mortar Clay Castable Clay Light Weight Castable Clay Plastic Clay Patching Material

SiO2 SiO2 Al203-

Clay Spray Material

High Alumina Mortar High Alumina Castable High Alumina Light Weight Castable Alumina Castable High Alumina Plastic

Al203 SiO2

Alumina Plastic High Alumina Ramming Material Alumina Ramming Material High Alumina Patching Material Alumina Patching Material High Alumina Spray Material Unshaped Refractories

Zircon Mortar Zircon Castable Zircon Alumina Ramming Material Zircon Spray Material Chrome Plastic Chrome Patching Material

ZrO2 SiO2 Al2O3

Alumina Spinel Castable Alumina Spinel Spray Material Alumina Spinel Injection Material

Cr2O3˚ FeO Al2O3 Al2O3 Spinnel (Al2O3˚MgO)

Magnesia Mortar

MgO

Magnesia Castable Magnesia Ramming Material Magnesia Spray Material Chrome Magnesia Mortar

Magnesia Dolomite Spray Material Alumina Magnesia Castable Magnesia Alumina Spray Material Carbon Castable

MgO Cr2O3˚ FeO MgO CaO Al2O3 MgO MgO Al2O3 C

12-11

Cocks Oven Cocks Oven Repair Ladle, Cocks Oven, etc Hot Stove, Boiler, etc Interior insulator of F’ce Proper Reheating Furnace, Incinerator Repair of Reheating Furnace and Incinerator, etc Repair of Blast Furnace, Reheating Furnace and Sintering Furnace, etc Materials for bonding bricks Interior finish of the furnace Interior insulator of Furnace various interior decoration Reheating furnace, Soaking Furnace, Incinerator, etc Reheating Furnace, EAF, etc EAF, Reheating Furnace, Soaking Furnace, etc Reheating furnace, Soaking Furnace, etc Repair of various furnace, Ladle Repair of various furnace, Ladle Blast Furnace, finex, Torpedo car, Sintering Furnace, Repair of various furnace, etc Bonding for Zircon bricks Ladle, etc Ladle, etc Repair Ladle Construction and Repair for Reheating furnace, Incinerator, etc Ladle, Turdish, Degasser, etc Ladle repair Repair materials for Ladle and degasser Bonding for Magnesia Carbon bricks LF, EAF, etc LF, EAF, etc Ladle, Turdish, Degasser Bonding for Magnesia Chrome brick Repair materials for Ladle furnace Ladle, Degasser, Snorkel, Turdish, etc Repair materials for Ladle, Degasser, Snorkel, Turdish, etc Blast Furnace, Finex, etc

Chapter 12 Refractories

Carbon Ramming Material Silicon Carbide Castable Silicon Carbide Spray Material Silicon Carbide Carbon Ramming Material Alumina Silicon Carbide Castable Alumina Silicon Carbide Spray Material Alumina Silicon Carbide Carbon Castable Alumina Silicon Carbide Carbon Mud Material Alumina Silicon Carbide Carbon Spray Material Alumina Silicon Carbide Carbon Accessories Material Magnesia Carbon Castable Magnesia Carbon Ramming Material Magnesia Carbon Spray Material Magnesia Carbon Accessories Material

SiC SiC C Si3N4 Al2O3 SiC Al2O3 SiC C

Blast Furnace, Finex, etc Repair for Torpedo Car and BF Repair for BF ,Hot Metal Ladle And Torpedo car, etc Blast furnace, Finex, etc Repair for BF ,Hot Metal Ladle And Torpedo car, etc Torpedo car,, Hot Metal Ladle, Iron Runner, etc Blast Furnace Tap hole Repair for iron runner and Torpedo car Repair materials for iron runner

MgO C

Ladle furnace Ladle furnace Ladle furnace repair Ladle furnace

4.0 Test and inspection standards 4.1 General 4.1.1

Scope of application This regulation is applicable to the test and inspection procedure of the refractory materials which would contact or not contact high temperature molten material like pig iron, molten metal and slag used in general by steel making process.

4.1.2

Inspection procedures (1) Unless otherwise specified in the purchase technical specifications provided by POSCO-Indonesia, this regulation shall apply to the test and inspection of refractories. (2) The fireproof material test and inspection items shall be classified into a direct test conducted by POSCO- Indonesia or a representative designated by POSCO- Indonesia, and a test conducted independently by the supplier. The supply shall obtain confirmation from POSCO- Indonesia in case a test is

12-12

Chapter 12 Refractories

conducted independently by the supplier. (3) In general, quantity and visual inspection, size inspection based on sampling, and provisional fabrication test shall be conducted directly by POSCOIndonesia; while the individual brick size inspection, strength test, refractoriness test or chemical tests shall be conducted by the supplier. (4) Even if an item does not fall under the category specified in the above paragraphs or other clauses separately by POSCO- Indonesia supplier, if POSCO- Indonesia requests an attended test, the supplier shall comply with such request. (5) If there is a difference of opinions regarding the product test and inspection procedures, decision shall be made according to the following order of priority: 1) Purchase specifications or contract specifications 2) Indonesia Standard and ISO 3) In-house regulations of the supplier or of the supplier’s partner. 4) Interpretations provided by a 3rd institution agreed between POSCOIndonesia and the supplier.

4.2 Inspection types and standards 4.2.1

Fireproof material inspection items and method

(1) SNI( 15-4936-1998 ) - Shape and dimension of fire brick (2) SNI( -- ) - Method of inspection for dimension of refractory bricks (3) SNI(15-0236-1989 ) - Testing method of bending strength for fire brick (4) SNI(15-0236-1989 ) - Testing methods for dimension of refractory bricks (5) SNI(15-0236-1989 ) - Method of measuring warpage of refractory bricks (6) SNI( 15-4936-1989 ) - Testing method for refractoriness of refractory materials and products (7) SNI( 15-0236-1989 & 15-4936-1998) - Testing method for apparent porosity, water absorption and specific gravity of fire bricSNI (8) SNI(15-0236-1989) - Testing methods for compressive strength of fire brick (9) SNI( -- ) - Test method for the rate linear expansion of refractory brick on heating (10) SNI( -- ) - Testing methods for refractoriness under load of refractory bricks (11) SNI( 15-1571-2004) - Testing method for thermal conductivity of insulating firebrick (12) SNI( -- ) - Testing methods for setting time of refractory mortars (13) SNI( 15-4936-1998 ) - Chemical analysis of refractory bricks and refractory mortars (14) SNI( 15-0236-1989 ) - Testing methods for modulus of rupture of refractory bricks and insulating fire bricks at elevated temperature

12-13

Chapter 12 Refractories

(15) SNI( 15-1571-2004 ) - Testing methods for reheat shrinkage of insulating fire bricks (16) SNI( -- ) - Testing method for gravity and true porosity of insulating fire bricks (17) SNI( 15-1571-2004) - Testing method for compressive strength of insulating fire bricks (18) SNI( 15-1571-2004)- Testing method for coefficient of linear expansion and shrinkage of insulation fire bricks during heating (19) SNI( -- ) - Testing method for modulus of rupture of insulating fire bricks (20) SNI( 15-1853-1990 ) - Testing method for spoiling of refractory brick and plastic refractories (21) SNI( -- ) - Testing method for permeability to gases of refractory bricks (22) SNI( 15-0809-2001 ) - Method of test crushing strength and modulus of rupture

of castable refractories (23) SNI( -- ) - Testing method for grain size of castable refractories (24) SNI( 15-4936-1998) - Testing method for the rate of linear change of high alumina and fire clay plastic refractories (25) SNI(--) - Testing method for grain size of light weight castable refractories (26) SNI( 15-0809-2001) - Testing method for permanent of linear change on light weight castable refractories (27) SNI( 15-0809-2001 ) - Testing method for bulk specific gravity of light weight refractories(method for molded goods) 4.2.2 Inspection standards (1) The following standard values obtained after conducting a quality inspection for the fireproof materials shall not be obtain from the average quality data of 1 lot of materials to be inspected, but shall be used as a minimum value which decides acceptance or rejection of the fireproof bricks. (2) Each edge damage, corner damage, face cracks or the level of crater occurrence of the individual fireproof bricks shall be visually checked based on the following standards:

Classification

Basis

State Diagram

12-14

Chapter 12 Refractories

- (H / L) ×100 ≤ 0.5 % - H : Max. 1.0mm (Real Measurement)

Bending

Chips

Corner - (A+B+C) ≤ 20mm - Permit 2 point Chips (Real Measurement)

Edge - (D+E) ≤ 10mm D : Less than 5mm E : Less than 5mm - Permit 2 point Chips (Real Measurement) Height Tolerance ( X)

- Permit less than 1.5mm Height Tolerance : (X) = [(B1-B2)- (b1-b2)] ☞ B1,B2: Basis length b1,b2: Real measurement

Taper

- (B-A) ≤ 1/300 x B

Surface Crack

- Surface : After measure with the eye, actually measure - Movable surface : Permit 1-fine-crack less than width 0.2 mm and length 20mm

12-15

P

Chapter 12 Refractories

Inner Crack

- Non-movable surface : Permit 2-fine-cracks less than width 0.25mm and length:40mm - 2-surface connection : Permit 1-fine-crac less than width 0.25mm and length 40mm - No permit the crack parallel to movable surface - Beat-sound inspection or observe after inner-cutting : No permission

Lamination

- Observe after inner-cutting : No permission

Segregation

- Actual measure after observing ,after inner-cutting - Movable surface : Permit 1 point width 5 mm and length:30mm - Non-movable surface : Permit 2 point width 10mm and length 40mm - Not permit others irregular aggregate arrangement (Judgment by inspection eye-measurement and/or picture) - Outer and inner Cutting : No permission

Spot or Fused Impurity Surface Dust

- Not permit the materials which does not integration bricks

5.0 Packing and Marking 5.1 Packing material and method : Following the paint and packing basis of ISZ part 5. Packing unit shall be basis on 20Kg, 500Kg and 1Ton according to products Material and others items shall be followed the General Contract Agreement. 5.2 Marking : Following the General Contract Agreement. Productions related MSDS(Materials Safety Data Sheet) shall be warning mark when packing.

6.0

Others : Productions related MSDS(Materials Safety Data Sheet) shall be submitted the MSDS.

12-16

Chapter 13 Safety Facilities

Chapter 13 Safety Facilities

13-1

Chapter 13 Safety Facilities

Table of Contents 1.0

Scope of application ................................................................................................

3

2.0

Types and Locations of Safety Facilities ............................................................

3

3.0

Design criteria ........................................................................................................

4

3.1

Stairs ...................................................................................................................

4

3.2

Fixed Ladder......................................................................................................

5

3.3

Safety Hand Rail ..............................................................................................

6

3.4

Scaffold ..............................................................................................................

6

3.5

Overpass.............................................................................................................

7

3.6

Protection Covers .............................................................................................

7

3.7

Working Passage ..............................................................................................

8

3.8

Enclosure .........................................................................................................

9

3.9

The Entrance ......................................................................................................

9

3.10 Power Door .......................................................................................................

10

3.11 Emergency Exit ..............................................................................................

10

3.12 Alarm Equipment ............................................................................................

10

13-2

Chapter 13 Safety Facilities

1.0 Scope of application This standard is applicable to the design criteria for safety facilities to be installed to dangerous parts and working places of equipment in the steel works. 2.0 Types and Locations of Safety Facilities The major dangerous working places where safety facilities are to be installed are as follows – however, depending on specific conditions of locations and equipment or structures, safety facilities need to be installed on other places where any dangerous factors exist: Classifications

Installation Locations

Stairs Fixed Ladder

Every floor, basement and machinery (such as valve) of more than 1 m height above the ground Openings of more than 1 m in height, tips of the footholds, both sides of stairs, edges of safe passage, and roof edges of a building used as safe passages to check equipment. High working places of more than 1 m from the Floor, where machinery and valves, etc. are to be operated, checked and maintained.

Safety Hand Rail

Scaffold

Overpass

Protection Covers Working Passage and Safety Passage Enclosure The Entrance Power Door Emergency Exit

Upper part of roller tables, conveyer’s crossing working places and any places not allowing access to the ground or underground of the parts where various machine are installed. Dangerous parts that may be rolled, narrowed, and collided due to any contacts with rotating axis, wheel, pulley and belt of power driven machinery. Passage to the working places. Passing area for operators in workplace. Places in danger of collision and Construction with operating elements in machinery, openings or tips of scaffolding, charging part of electric facilities such as transformer room, hazardous workplaces such as conveyor belts pulley. The entrance of working places Power-driven doors Workshops or buildings of workplaces where explosive, ignitable, oxidative, flammable, corrosive and poisonous substances and combustible gases, etc. exist.

13-3

Chapter 13 Safety Facilities

3.0 Design criteria 3.1 Stairs 3.1.1 Strength Stairs and stairs landing shall be more than 4- safety factor and of structures having strength enough to endure load of more than 500kg/m2 for main office building.. 3.1.2 Width and Gradient (1) Every stair shall be of more than 1 m wide, except for refueling, maintenance, emergency and spiral stairs. (2) If angle of gradient is within 30˚ ~ 45˚ to the horizontal, stairs shall be installed. (Except for maintenance) (3) For angle of gradients less than 30˚ ramps, and more than 45˚ a fixed ladder shall be installed. 3.1.3 Stair Landing Height Install a stairs landing height to be followed as per OSHA Standard. 3.1.4 Ceiling Height There shall be no obstacles within 2 m from floors, scaffolding or ramp surfaces (hereinafter, “Floor”). (Except for refueling, maintenance, emergency and spiral stairs) 3.1.5 Tread and Height (1) Minimum width of stair tread should be as per OSHA Standard. (2) Any anti-slide measure shall be taken to the rail of a tread. (3) The stairs of each floor shall have prescribed width and height. (4) Stairs and entrance floors, fabricated by means of perforated plates, shall be of structures preventing wrench and other tools from falling. 3.1.6 Safety Hand Rail of Stairs (1) A safety hand rail shall be installed on any open sides for the stairs of more than four steps. (2) A safety hand rail shall be installed on the edges of both sides for stairs exceeding 1m of width. (3) A safety hand rail for supporting shall be installed on one side for stairs only if both sides are blocked and width is less than 1 m. (4) A safety hand rail shall be installed on the center of stairs exceeding 2.25m of width.

13-4

Chapter 13 Safety Facilities

3.1.7 Maintenance Stairs (1) The effective width for the maintenance stairs of a room and basement or for the maintenance stairs leading to an inspection stand around machinery shall be more than 56 cm. (2) A maintenance stair shall have an inclination of less than 60˚ and be more than 15 cm wide. 3.2 Fixed Ladder 3.2.1 Structure (1) For metal parts or accessories, carbon steel, stainless steel or other materials having more strength shall be used. (2) For ensuring safety when going up and coming down, the upper part of a ladder shall be designed, projecting more than 60 cm over from a wall-meeting point. (3) The height between Floor and a ladder platform shall be within 50 cm. (4) The distance between a ladder platform and the wall of a building or facility shall be more than 30 cm. 3.2.2 The Height of Ladder Landing (1) Ladders with more than 10 m high, shall be provided a ladder landing or a platform every 5 m. (2) Ladders shall be separated to install a ladder landing where top and bottom may not be in a straight line. 3.2.3 Width and Height of Platform (1) The width of platform shall be 40 cm to 50 cm and the height shall be 25 cm to 35 cm. (2) The width and height of every stair shall be prescribed. 3.2.4 Backrest (1) The vertical plate bar with more than four lines of a backrest shall be installed and the gap between the vertical plate bars be 25 cm to 30 cm. (2) The horizontal plate bar of a backrest shall be 60 cm to 65 cm in diameter and the gap between the horizontal plate bars be within 1.2 m. (This bar can be installed (3) The distance between a floor and the bottom of a basket is less than 2 m. (However, for installation of a fixed ladder to a stairs landing whose height is more than 3 m from the ground, the ladder shall be of structure preventing operator from falling down between the bottom of backrest and a safety hand rail.)

13-5

Chapter 13 Safety Facilities

3.3 Safety Hand Rail 3.3.1 Structure (1) The upper rail installation height shall be 100 cm to 120 cm above floor. (2) The distance between supports shall be less than 1.5 m. (3) One lines of a middle rail between Floor and upper rail shall be installed. (4) A distance of at least 4 cm between a safety hand rail and a wall or other protrusions shall be kept (5) For installation of a safety hand rail to a stair, the hand rail shall not obstruct the stair, its every step and stair landing. (6) Upper rail and middle rail shall be parallel to Floor over the entire rail. 3.3.2 Strength of Materials (1) A safety hand rail shall be strong enough to endure more than 100 kg load applying from any point to any direction. (2) For upper rail, use a metallic pipe with more than 2.7 diameter or stronger materials. (3) For middle rail, use a metallic pipe whose diameter is more than 1.9 cm or stronger materials 3.3.3 Toe Board A toe board whose height is more than 10 cm from Floor shall be installed to any safety hand rail installed in parallel (However, any locations where no object is in danger of falling/thrown onto Floor or any required precautions are taken, i.e. a net is installed to prevent any related risk. 3.4 Scaffold 3.4.1 Strength of Structure and Material (1) Materials for a scaffold shall be strong enough to endure the working load. (2) A scaffold, when to be made using materials with holes, shall be of structures preventing wrench and other tools from falling. (3) The support for a scaffold shall be made of metallic materials for structure having enough strength not to be fractured by the load. (4) A scaffold shall be securely fixed to a support, not to sway or fall off. 3.4.2 Installation of Safety Hand Rail (1) If operation or manipulation parts of machinery are too high or low comparing with operator’s height and other physical conditions, install a scaffold of appropriate height. (2) The following safety hand rail for falling down prevention shall be installed to a foothold located more than 1 m above the ground :

13-6

Chapter 13 Safety Facilities

1) A safety hand rail shall be strongly made of metallic materials having high strength for pipe structure (Refer to Safety Hand Rail / OSHA Standard). 2) A safety hand rail shall be installed over the entire foothold but working range. 3.4.3 Tiptoe Board and Other (1) A tip board, more than 10 cm in height, shall be installed on the edge of a platform (including pillar-shaped) where a safety hand rail is installed. (However, any locations where no object is in danger of falling/thrown onto the Floor or any required precautions are taken, i.e. a net is installed to prevent any related risk shall be excluded.) (2) For a scaffold for moving, take prevention measures required to prevent risk behavior while moving the scaffold. 3.5 Overpass 3.5.1 Strength of Structure and Materials (1) A walking bridge shall be installed in indoor passage shape or stair shape. (2) Gradient of stair, height of tread, installation method of safety hand rail, strength of materials shall be in accordance with the installation method of stairs. 3.5.2 Passage Width (1) The passage or stair width of a walking bridge shall be wider than that of maintenance stair. (2) A safety hand rail in accordance with that of stairs shall be installed on the edges of both sides of a walking bridge to prevent overturning and falling. 3.6 Protection Cover 3.6.1 Materials Use a perforated plate, expanded metal, I-beam, steel pipe or metal mesh attached to a frame not empty. Or use materials appropriate for each purpose. 3.6.2 Conditions (1) It shall prevent access to dangerous zones while operating. (2) It shall be installed or attached to machinery as much as possible, to prevent bodily contact with power-driven object. (3) It shall be easy for refueling, checking, controlling and repairing of machinery. (4) It shall provide abrasion-resistance and shock-resistance, and shall not be easily inoperative.

13-7

Chapter 13 Safety Facilities

(5) Any protrusion, sharp angle, rough edge and others that may cause any accident shall be prevented. (6) It shall provide strength, durability and corrosion- resistance. 3.6.3 Specifications of Safety Net (1) Safety nets shall be designed to prevent any physical contact with machinery and to protect a man from flying objects or material during operation. (2) Specifications of a safety net of guard type are as follows: Y= (X/10)+6 (mm) Y= specifications of the net (mm), X= distance from hazardous point (power driven object) to the net (mm). ※ However, these specifications are applicable only when the distance from hazardous point to the net is less than 760 mm. (3) Specifications of general safety net are as follows: Y=0.15X+6(mm) ※ However, these specifications are applicable only when the distance from risky point to the net is less than 160 mm. (If X≥160mm, Y=30) 3.7 Working Passage 3.7.1 Design Conditions (1) Passage marks shall be made in the passage if required. (2) A lighting facility of more than 75 lux (lx) shall be installed for operator to safely pass through a passage. (3) No obstacle shall exist within 2 m height from the passage floor. (Any obstacles such as holes, grooves, protruding valves and pipes shall not exist for the safety of worker passing by.) (4) The passage shall be made for operator not to slip on the passage floor, tread and stair landing (5) Prevention measures shall be taken against sliding wherever a sliding accident could frequently occur such as stairs, ramps and elevator boarding gates. (6) For working passages for every kind of equipment or material, keep an appropriate distance to protect workers from constriction, collision and flying objects. 3.7.2 Structure of Temporary Passage (1) The structure shall be rigid installed. (2) The structure shall be inclined less then 30˚.(Except for installation of stairs as well as a temporary passage with strong handles less than 2 m in height.) (3) When inclined more than 15˚, the structure shall be installed to protect operator from slipping. (4) A safety handrail shall be installed to the passages of a place where a falling accident could occur.

13-8

Chapter 13 Safety Facilities

(5) When the length of a vertical underground passage that is temporarily installed is more than 15 m, stair landings shall be installed every 10 m. 3.7.3 Structure of Ladder-type Passage (1) The structure shall be rigorously installed. (2) The gap between footholds shall be identical. (3) Appropriate distance between a scaffold and a wall shall be provided. (4) When the length of a ladder style passage is more than 10 m, install stair landings every 5 m. (5) A ladder style passage shall be inclined less than 80˚. (6) The structure of a fixed ladder shall be applied to those of the other ladder style passages. (7) Install a ladder style passage with stair style as much as possible. 3.7.4 Passage for Crane (1) The width shall be more than 60 cm when installing a passage between a traveling or jib crane and a structure or equipment. However, more than 40 cm is permitted for the contacting part of the passage to the pillar of a structure. (2) For the following items, the gap between a structure and a wall shall be less then 30 cm. 1) The gap between a wall and the end of a passage through a cabin or steering wheel. 2) The gap between a crane girder and the passage end of a crane girder. 3) The gap between a wall such as a structure and the passage end leading to the passage of a crane girder. 3.8 Enclosure 3.8.1 Structure (Palisade) (1) The structure shall be rigorous with a metallic pipe and angle for structure, and other materials having enough high strength. (2) Install pillars every 2 m in an enclosure, and upper crossbeam shall be strong enough to endure more than 100 kg load applying from any point to any direction. (3) The structure shall be made of rigorous materials having no defects, and its every sharp angle shall be treated to present round shapes. 3.8.2 Specifications (Palisade) (1) The Specifications of an enclosure are decided in accordance with those of the protection cover (those of safety net). (2) The distance and height between an enclosure and a hazardous point shall be determined to prevent operator’s body (e.g. hands) from contacting to dangerous parts.

13-9

Chapter 13 Safety Facilities

3.9 The Entrance (1) The entrance for passenger shall be installed near to a doorway for cargo handling equipment (except for emergency exit). (2) Install alarm devices such as an emergency light or emergency bell to prevent an operator from contacting with cargo handling equipment at the passages adjacent to doorways. 3.10 Power Door (1) The Take appropriate prevention measures, e.g. installation of an emergency stop device, to a power driven door to 2.5 m height for stopping operation in emergency or dangerous status because operator could be stuck in the door. (Not applicable when a safety device is already installed to operate the door only if there’s no one in dangerous zone, or when a specially assigned an operator operates the door all the time.) (2) An emergency stop device shall be easy-to-find and easy-to-operate for operator. (3) The door, once power is off, shall stop immediately. (Except fire doors) (4) The door could be manually opened and closed. (5) During manual operation, the door shall stop with control units immediately. 3.11 Emergency Exit (1) In addition to gateways, more than one emergency exit shall be installed to a workshop where dangerous materials are manufactured or handled, as well as a construction containing the related workshops. (2) The direction of the exit shall be opposite to that of a gateway and shall be more than 3 m away from the gateway. (3) The horizontal distance between each part of workshops and an emergency door or a gateway shall be less then 50 m. (4) The width shall be more than 0.75 m and the height shall be more than 1.5 m. (5) The door for the exit shall open to the direction of a shelter and open indoors without fail, and the sign of emergency exit shall be installed at the inside/outside of the door. 3.12 Alarm Equipment Alarm equipment or apparatus shall be installed, to inform promptly during an emergency, to an indoor workshop accommodating more than 50 workers at ordinary times or having gross area of more than 400 m2.

13-10

Chapter 14 PUMPS

Chapter 14

14-1

PUMPS

Chapter 14 PUMPS

Table of Contents 1.0

SCOPE OF APPLICATION .................................................................................................... 3

2.0

CENTRIFUGAL PUMPS ......................................................................................................... 3

3.0

2.1

General ................................................................................................................................................ 3

2.2

Operating Features .............................................................................................................................. 3

2.3

Construction ........................................................................................................................................ 5

2.4

Methods of Sealing ............................................................................................................................. 6

2.5

Electric Motors .................................................................................................................................... 6

2.6

Base Plates .......................................................................................................................................... 6

2.7

Installation ........................................................................................................................................... 6

SUMP PUMPS ........................................................................................................................... 6 3.1

General ................................................................................................................................................ 6

3.2

Operating Features .............................................................................................................................. 6

3.3

Construction ........................................................................................................................................ 7

3.4

Installation ........................................................................................................................................... 7

3.5

Cable Termination ............................................................................................................................... 7

14-2

Chapter 14 PUMPS

1.0 SCOPE OF APPLICATION This standard is applicable to the general technical specifications used to purchase centrifugal pumps and sump pumps for KRI, or used as the design and inspection standards for the centrifugal pumps and the sump pumps carried out by the supplier at the request of KRI. 2.0 CENTRIFUGAL PUMPS 2.1 General Each pump unit shall be complete in all respects and shall include prime mover, coupling and guard, bedplate, holding down bolts and all integral piping. Pumps shall be capable of withstanding accidental reverse rotation without damage. Any residual axial force not hydraulically balanced by the pump impeller/rotor shall be accommodated by the pump bearings. 2.2 Operating Features Pumps shall be horizontal centrifugal split casing type directly coupled to motor through flexible coupling and mounted on common sturdy baseframe. In case such pumps are not available for a particular duty condition, end suction back-pullout type pumps with spacer coupling may be considered. Pumps shall be suitable for a capacity range of 35% to 120% of duty point capacity and the pump models selected shall have drooping characteristic curves. Nonoverloading type power curve of pump is preferred. . Minimum one (1) No. pump shall be provided as stand-by for each pump group.. All pumps shall have rated speed not exceeding 1500 rpm as far as possible. Motor ratings for all the pump sets shall be selected such that de-rated kW rating of the motors shall be more than the brake kW drawn for maximum positive frequency variation in power supply or maximum power drawn within the stable range of operation of the pump whichever is higher. All pumps shall be fitted with bush type coupling.

type coupling or flexible love-joy or pin and

All pump sets shall be complete with drain plug, vent cock, coupling, coupling

14-3

Chapter 14 PUMPS

guard, base-frame with foundation bolts, nuts and gaskets: All pump sets shall comply with the requirements of International Standard However, no negative tolerance on head, capacity and efficiency of pump will be accepted. Pump sets shall be suitable for the required duty conditions and shall be designed and constructed for 24-hours' continuous duty at full load. Pumps shall be so selected as to have a maximum capacity of not less than 120% of the rated capacity. Pumps shall be selected so as to have stable characteristics. The capacity head curves shall be continuously drooping from the shut off point to the operating point and shall be suitable for parallel operation without any possibility of hunting. The direction of rotation of the pumps shall be clockwise looking from drive-end. The direction of rotation shall be clearly marked on the pump The pump casing shall be tested to withstand a pressure of 1.5 times the shut off pressure or twice the rated pressure whichever is higher. The pumps shall preferably be equipped with antifriction bearings with grease lubrication. Pumps and motors shall be mounted on a common base-frame fabricated from mild steel. The base-frame shall be stress relieved after fabrication and machined. The base-frame shall be adequately sized and shall be suitable for fixing coupling guard. Convenient access to the fixing bolts associated with the equipment and base-frame shall be ensured. The following accessories shall be supplied with each pump set: a) Matching flanges complete with bolts, nuts and gaskets at both suction and delivery ends of pump sets. b) Air cock on top of pump casing c) Drain pipes for collection and disposal of gland leakages d) Foundation bolts, nuts and gaskets Material of construction of the pumps for various services shall be as indicated

14-4

Chapter 14 PUMPS

below: Sl. No. a)

b)

c)

Service

Fluid

Material of construction

Critical application like Demineralised Casing : Cast steel to ASTM A216 Gr. BF closed cooling, water / soft WCB Hood and Lance water cooling for converter, Impeller : Stainless steel to CF8M mould & machine cooling for caster etc. cooling Shaft : Stainless steel to AISI 410/EN 19, SS to AISI 410/EN 19 Industrial cooling water Service water, Casing : Cast iron (ICW), Direct cooling contaminated ( for shut off pr. Up to 16kscg) water water, soft water Cast steel to ASTM A216 Gr. WCB (DCW), general service (for shut off pr. above 16kscg) water, soft make up water etc. Impeller : Cast iron for ICW, general service water and soft water . Stainless steel to CF8M / 2% Ni Cast iron for DCW.

Waste water

Sludge/slurry

Shaft : Stainless steel to AISI 410/EN 19 Casing & impeller : 2% Ni Cast iron Shaft : Stainless steel to AISI

410/EN 19

All horizontal pumps with suction pressure above 3.0 kscg in clear circuits shall be provided with balanced type mechanical seal. Pumps with suction pressure up to 3.0 kscg shall have gland packing. Diesel engine driven pumps shall have air-cooled, 4-stroke diesel engine with dedicated forced lubrication system with requisite control for auto start during emergency.

2.3 Construction The pumps shall be constructed of materials specifically selected for their duty and to resist deterioration by cavitation, pitting, erosion and corrosion. Specifically, impellers handling scale water have to be casted in modular iron, unless more resistant material is specified. A corrosion allowance of Max. 3 mm must be foreseen on pump casings.

14-5

Chapter 14 PUMPS

2.4 Methods of Sealing Pumps shall be suitably sealed to prevent undue loss of liquid and be designed for safe and efficient operation where acids or alkalis are involved. Packing and mechanical seals shall be installed in accordance with their manufacturer’s recommendations. General service water shall be used for gland and seal services, and discharge water shall be routed to site drainage. 2.5 Electric Motors Refer to Chapter 07 Electrical Equipment of ISZ-2. 2.6 Base Plates All pumps and motors shall be mounted on a common base plate 2.7 Installation Pumps and related pipelines must be installed in such a way that no vibrations or forces can be transmitted to each other. 3.0 SUMP PUMPS 3.1 General This Section covers vertical centrifugal submersible sump pumps for general drainage use. Sump pumps shall be in accordance with Section 2.0 above, except where modified below. 3.2 Operating Features Portable submersible free standing type centrifugal pumps shall be provided. Submersible pumps shall have rated speed not exceeding 1500 rpm as far as possible.

Material of construction of the submersible pump sets shall be as follows:

14-6

Chapter 14 PUMPS

Casing : Cast iron Impeller : Stainless steel to CF8M Shaft : Stainless steel to AISI 410 / EN 19 Suction strainer : Cast iron Dewatering pumps shall be provided with mechanical seal. Submersible type motor, squirrel cage induction type with water and oil resistant winding as per International Standard shall be provided. The following accessories shall be supplied with each submersible pump set: a) b) c) d)

Control panel Level probes for auto-start/stop operation Power and control cables Flexible hose

3.3 Construction Sump pumps shall have an integral base and suction strainer. The motor and pump shall be integrated to form a single compact unit. 3.4 Installation Where permanently installed, pumps shall be mounted in accordance with the manufacturer’s instructions in sumps of suitable dimensions. Pipe shall be coupled to pumps so as to prevent loads being transmitted to the pump casing. 3.5 Cable Termination Pumps shall be provided with suitable waterproof cable glands and terminations as necessary.

14-7

Chapter 15 Pressure and non-pressure vessel

Chapter 15

PRESSURE AND NON-

PRESSURE VESSELS

15-1

Chapter 15 Pressure and non-pressure vessel

Table of Contents 1.0

2.0

PRESSURE VESSELS .............................................................................................................. 3 1.1

General ................................................................................................................................ 3

1.2

Specification ....................................................................................................................... 3

1.3

Construction ....................................................................................................................... 3

1.4

Fabrication .......................................................................................................................... 3

1.5

Rating Plates ....................................................................................................................... 3

ATMOSPHERICALLY VENTED TANKS .......................................................................... 4 2.1

General ................................................................................................................................ 4

2.2

Specification ....................................................................................................................... 4

2.3

Construction ....................................................................................................................... 4

2.4

General Requirements ..................................................................................................... 5

2.5

Internal Protection............................................................................................................. 5

2.6

Site Testing ......................................................................................................................... 5

15-2

Chapter 15 Pressure and non-pressure vessel

1.0 PRESSURE VESSELS 1.1 General This Section relates to the requirements for unfired pressure vessels but does not include those where internal pressure is solely due to the static head of the liquid contained therein. 1.2 Specification Pressure vessels shall be in accordance with The design conditions shall allow for the most severe combination of internal and external loads and forces to which the vessel may be subjected 1.3 Construction All vessels shall be provided with inspection and/or access openings to allow internal visual inspection. All vessels shall incorporate suitable lifting lugs. All internal parts spanning across a chord or diameter of the vessel shall be provide with a means for allowing differential expansion between the part and the shell. Baffles or wear plates shall not be welded directly to the shell or head, but shall be bolted to support attachments welded to the shell or head. 1.4 Fabrication All welding and stress relieving shall be in accordance with ASME Section VIII Pressure Vessel/SNI:(13-3498-1994). 1.5 Rating Plates All vessels shall have permanently attached a rating plate giving information regarding design, working and test pressures, vessel empty and in-service weights and other manufacturer’s details (as for example, date of last test), as well as other specific requirements.

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Chapter 15 Pressure and non-pressure vessel

2.0 ATMOSPHERICALLY VENTED TANKS 2.1 General This Section relates to the requirements for above ground liquids storage tank vented to atmosphere where the working conditions do not exceed the static pressure due to the liquid stored and a temperature of 90℃. It does not apply to domestic water cisterns or reinforced concrete storage vessels. 2.2 Specification Tanks shall be in accordance with the relevant specifications taken from the national/international standards as per contractual agreement. Tanks shall be designed to withstand all loads imposed on them during construction, testing, operation and maintenance. 2.3 Construction Tanks shall be fitted with a tight fitting lid, or roof to prevent the ingress of dust, sand, vermin or other foreign matter. A freeboard of at least 200 mm shall be maintained during operation, and any devices necessary to prevent surging of the contents shall be fitted Any level control devices shall be mounted in still wells and shall be removable without draining the tank. All tanks shall be provided with an externally visible calibrated contents gauge and a dip tape. Internal and external access ladders and walkways shall be provided. All tanks shall be provided with inspection and/or access openings to allow internal visual inspection. Vents shall be 80 mm minimum diameter with swan neck and vermin proof screens. Visible overflows and valve drain connections shall be fitted. Draw out sumps shall be fitted as appropriate. Sectional tanks shall be erected with external flanges. Site welded tanks shall be provided with all necessary construction aids.

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Chapter 15 Pressure and non-pressure vessel

2.4 General Requirements Atmospheric suction tanks for main cooling circuits must be big enough to catch all water which can run during a stoppage of the system by force of gravity from the system towards this tank. This must be ensured when the tank has the max. water level during normal operation. The min. operational water level (min.-max. transmitter water level control) must be at least 30% higher than the required NPSH of the system and the pump or pump group whatever is worse under the actual mode of operation. The required NPSH of the pump or pump group should be taken +15% higher as the design characteristic of the pump or pump group. 2.5 Internal Protection Sectional steel tanks shall be galvanized prior to dispatch, and painted internally after erection with a approved non-toxic bitumastic based paint. Site welded tanks shall be sealed internally after erection and painted internally with the same paint as above. All painting and protection shall be in accordance with Part 5 of ISZ-1. 2.6 Site Testing Site fabricated and site erected tanks shall be tested in accordance with the relevant design code and local regulations.

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