1G Contract Documents IG Eneray Eisen by Ecologia Coa ally Managorent a Prjen = neve and Breton Eure Soa Cay arageret Package Cf3 - Procurement and Erection of Equipment fora New Stockyard at OCM Temnava Volume It UPDATED TECHNICAL SPECIFICATION Part 4: MECHANICAL EQUIPMENT §, CORROSION PROTECTION AND SCAFFOLDING WORK (On the site in the course ofthe erection progress, jointly used scaffoldings and platforms to be erected forall works are to be the responsibilty of the Contractor for mechanical equipment. Detailed agreements are to be made between the mechanics, electrical engineering and corrosion protection pats, whereby, itis particularly to be taken into account thatthe scaffoldings and platforms are to be required nearly until the end of the electrical technical erection work. 5.1. GENERAL PRELIMINARY REMARKS: ‘The specication below covers execution of the corrosion protection work atthe spreader forall within the scope of the realisation of the measure, This specification defines preparation and corrosion protection of workshop subassemblies and components, work on the instalation and repair of damaged protection. With al standards applied on corrosion protection it, should meet the oftera for @ long-term corrosion protection of min, 15 years. Guarantee period min. 5 years. The application must be achieved by spray of air andior by use of brushes. Intermediate profles area, cutouts and inner surfaces of the connecting points and bolts and head rivets shall be pained by hand, using appropriate tools in accordance with a predetermined coating system. Description of production process for manufacturers coating should be taken into account in all circumstances. All ‘works to protect against corrosion should be done professionally and in accordance withthe latest developments in this field In any case, should ensure proper qualty of works performance without flaw, without a scars, etc... and to bring the individual thickness of the coating. By agreement with the Employer, decision making on the coating craoks and joints can be made in terms of mutual approval. lt should to be avoided excessive coating thickness. The limit value is determined by the specification of the paint factory and acc. to the DIN EN ISO 12944. With RAL colours should be achieved a unified coating glow. If at the site uses are used abrasive blowing, surfaces blown away should be perfect and in accordance with a predetermined structure ofthe coating, so thatthe minimum thickness of dry coating is achieved as permitted under the specified condition. Performance of works must be provided in accordance withthe latest developments in ths field for all services related to protection against corrosion. {protection against corosion service is to be performed by the Subsuppler, he must be named inthe offer. The implementation is to be based acc. to DIN EN ISO 12944, DIN 18364, generally recognized safety, technical and industrial and medical regulations (UVV - accident - prevention rules), the latest developments and relevant regulations of Employers obligations in terms of the insurance company as well as DIN EN iSO 1461 and DIN EN 180 14713 on hot galvanized surfaces, excluding amendments to ths point For all screwed and riveted connections (GV and GVP connections), the striking surfaces are to be prepared pursuant to DIN 18 800, Part 7, tem 3.3. Coating is only possible with express approval by Employer. tis permitted covering by coatings which do not reduce the coefficient of friction with thickness up to 40 microns (to prevent corrosion in the joint due to possible moisture penetration). In other screwed and riveted connections, the areas planned to be covered are to be furnished with the specified corrosion protection system. Welding work on the construction site is to be reduced to that necessary. Therefore mountings for example for elect! instalation are to be connected to the main stee! structure by clamps system with sorews. Contact corrosion is to be avoided at al costs taking into account Item 5.10 of DIN 12944. Alltypes of fixtures, leveling piates and lubricating pipes are tobe in galvanised design. The scope of service also includes the constant cleaning of external rust during the installation causes for example by grinding and ding chips or other cleaning. interfaces of galvanised material are after surface preparation to be properly furnished with abasic and covering coating Under no circumstances may zinc spray be used. Volume part 200 of 248 2D1 conta Doan A Project © ~ Procurement end Erection of Equoment for Coal Quality Management ranch eer nde epee sso AST on Volume It UPDATED TECHNICAL SPECIFICATION Part 4; MECHANICAL EQUIPMENT The Contractor has to submit Performance Certificate stating the current executor of related services for corrosion protection Stipulations regarding corrosion protection also apply to all Contractors and Subsupplers. Al areas necessary for the consideration in the offer are to be determined by the Contractor in a way that it can be verified and comprehended by the Employer. The detailed assessment should include all the required unit prices. The Employer assumes that the quantity survey will be calculated. The quantity survey is fo be submitted to the client when the construction site is opened. Should the quantity survey be calculated via weight, the conversion factor is to be shown in the offer 5.2 STEEL STRUCTURE INCLUDING STEPS, PLATFORMS, RAILINGS, AND LADDERS, PROTECTIVE GRATINGS, WALKWAYS, DRIVE CONSOLES ETC. ‘The steel construction isto be designed so thatit issuable for corrosion protection pursuant to DIN EN ISO 12944, Le. the design is to minimise the accumulation of water and sand etc., and in the case of open hollow components, and suificient openings fr air circulation and drainage are tobe provided. Spot welding isto be avoided in the area where the alkaline tanks are to be positioned. Railings, ladders and scaffolding as well as protective gratings are to be delivered for new equipment with a hot- ‘galvanised design taking nto accounts above-mentioned DIN EN ISO. 5.3. SURFACE PREPARATION AND COATING — UNTEMPERED AREAS Surface pretreatment Allareas are to be blasted in the workshop in the standard percentage purity Sa 2.6 pursuantto DIN EN ISO 12944- 4. Itis tobe ensured that the Sa 2.5 biasted surface receives the basic coating immediately after surface preparation {to avoid rust fim). Itis recommended that the application of protection in workshop conditions. ‘All basic materials prior to processing must be sanded. If this is not possible, then some in the welding area by some appropriate procedure is to be achieved the level of surface preparation St 2. In accordance with DIN EN ISO 12944-3, all individual parts must be processed so that painting can be done. Erection connections for welding connections on the construction site are to be covered up in accordance with the \width of the welding influence zone. After assembly by welding, the surface area is to be prepared by manual rust removal (P St 3), with any burned coating stil present being removed atthe same time. Site connections for weld joints on the site are to be glued in accordance with the width of the welding zone of influence. To rule out adhesive problems, the area is to be cleaning of any residual glue. If assembly is to take place by sorewed connection, the assembly areas must have a proper expert KS corrosion protection with a thickness of 240 um, Erection surfaces with old coatings on the existing construction are always partially to be treated with a standard purity degree P Ma (machine-grinding) and/or P St 3 prior to on-site erection, i. e. existing coating and rust are to be removed prior to coating. ‘After erection (by way of welding) the surface area is to be prepared by mechanical manual derusting (P St 3), whereby, any still existing, burnt coating is to be removed as well, in order to exclude bonding problems the area is to be cleaned to remove possible adhesive residues. ‘The control of corrosion protection made according to DIN EN 1944-7. Performance and supervision of painting, 28 well as to {SO 2808 by setting the coating thickness (wet sediment) Volume Wt, part 1 201 of 246, &‘Ee Contract Documents G Energy Etclancy by Ecological Goa! Quality Management projet Cx Prourement sn econo Eaupment fer Coa Quay Maragement package C8 Procrement an eracton of upmen for 9 New Stora el GM Ternava Volume It UPDATED TECHNICAL SPECIFICATION Part 4: MECHANICAL EQUIPMENT 5.4 STEEL CONSTRUCTION INCLUDING STAIRS, PLATFORMS, RAILINGS, VERTICAL LADDERS, PROTECTIVE GRATINGS, WALKWAYS, DRIVE CONSOLE ‘The steo! construction is to be erected in a corrosion-proof manner in accordance with DIN EN ISO 12944, i € through the constructional design, among other things, particulary the accumulation of water, sand et. is to be minimised, and with open hollow members sufficient air circulation and drainage holes are to be provided. Spot ‘welding is to be avoided in the area where the alkaline tanks are to be postioned. Ralings, vertical adders and frame sections as well a protective gratings are, in case of new installations, to be delivered with hot-ip galvanised finish taking into account the mentioned DIN EN ISO. Coating system to perform according to DIN EN ISO 12944-6, edition 2007, ‘The respective minimum dry layer thickness is a target value, ie. no measured values should exceed this target ‘The Employer assumes that the top coating will also be carried out in the workshop. However, the Contractor is free to decide whether to carry out the top coating depending on the erection technology in the workshop or after assembly on site Coating is to be performed with: - 1x 2K epoxy resin high solid zine phosphate ~ basic coating, RAL 7001, 160 um = 1x2-K -PURIAY micaceous iron ore top coating, RAL 5012, 80 um The respective minimum dry coating thickness is 240 um With the consoles the bearing surface for the drives is to be provided with a 2K-EP - zinc phosphate ground coating in a coating thickness of 60 jm. To all other surfaces applies a coating thickness of 240 jm with the above mentioned coating system. Coating System Railings and Vertical Ladders, hand ~ ras, and gangways 4.x 2:K - epoxy resin - high-solid - zinc phosphate - basic coating, RAL 1021, 160 pm - 2x 2:K-PURIAY - protective coating, RAL 3020, 2x40 ym Equivalent proposals for corrosion protection and coating systems are allowed. The Contractor was indicated the detailed specification in the offer. 5.5 COATING SYSTEMS FOR GEARS, DRIVE DRUMS, ELECTROTECHNICAL EQUIPMENT AND MECHANICAL INSTALLATIONS, LUBRICATING INSTALLATIONS Detaits on corrosion protection with drums are contained in the respective delivery requirements. To any other supplies of mechanical installations and equipment ‘shall apply: Outside area~ binding agent base 2K EPIPUR, 240 ym Inside area ~ binding agent base 1K or 2K, coating thickness 120 jm. o lubricating installations and lubricating lines and hydrautic is to apply the fotowing principles: Installaions (non-coated) etc located in the lubricating container must exhibit a coating in a coating thickness of =/>120 um on binding agent base 2K-EP/PUR, Installations, ss ec. in the outside area must exhibit a coating thickness of =/> 160 ym on binding agent base 2K-EPIPUR or an equivalent surface coating ensuring long-term corrosion protection. Installations (coated ~ galvanised according to DIN $0964) et. exhibiting a coating thickness of => 18 jm are not provided with any additonal coating. Volume t part # 202 0f 248je) Contract Documents {9}} Energy Efficiency by Ecological Coal Quality Management Project C ~ Procurement and Erection of Equipment for Cosi Quality Management Package CA - Procurement and Erection of Equipment for @ New Stockyard at OCM Tamnava Volume Il UPDATED TECHNICAL SPECIFICATION Part 4: MECHANICAL EQUIPMENT Incase that this value is fallen short of inthe outside area additional coating on binding agent base 2K-EP must be provided, or an equivalent surface coating must be in place including proof ofthe duration of protection, For all fields of performance corrosion protection isto be implemented in a way that a long-term corrosion protection of > 15 years is achieved in accordance with DIN EN ISO 12944 5,6 ACCOMPANYING CORROSION PROTECTION AND ELIMINATION OF TRANSPORT AND ERECTION-RELATED DEFECTS ‘Surface Preparation. Within the scope of defects elimination it is done by means of mechanical manual derusting, St 3 and P Ma according to DIN EN ISO 12944 - 4, whereby, welding residues, bumt and blackened paint, loose old coatings and rust as well as all other impurities are to be removed. With transportrelated defects, other inclusions in the coating are to be removed as well. Arresting/hanging points ‘and devices are to be selected in a manner that they do not cause any damage to the coating, The same is to be taken into account with the workmanlike storage on the site. For that reason the intermediate drying tes determined by the coating materia manufacturer are to be observed under all circumstances until the time of transport. Coating with 2K - epoxy resin - OT basic coating, RAL 7001, 80 4m, 2K - epoxy resin - micaceous iron ore protective coating, RAL 5012, 80 um and 2K - polyurethane/AY- micaceous iron ore protective coating, RAL 5012, 80 jim. Damaged areas are to be retouched partially; otherwise, allover coating is executed so that the minimum coating thickness of 240 im is achieved in these areas as well. With welding spots, defects elimination is always executed (on both sides of the zone of influence. Transport-related defects are to be eliminated at the sole expense of the Contractor. Lubrication lines that are affected by emission control water should generally be installed in stainless austenitic steel 1.4304. This applies to the whole plant. 5.7 HOT GALVANISED AREAS: Alt hot galvanised areas of ralings, scaffolding and protection grilles are to be ensured a zinc thickness of =/> 60 um. Damaged to the zinc layer is to be rectified pursuant to DIN EN ISO 1461 using MG 46. Incase the defect reaches down to the steel, after coresponding surface preparation with surface-tolerant ground and protective coating (180 jim], repair work has to be conducted deviating from the DIN. Fluxing agent and zinc ash residues as well as zinc tps are principally to be removed 5.8 SUPPLEMENTARY WoRKS 5.8.1 PROTECTIVE MEASURES ‘The course of erection and, therefore, also the requirements with regard to protective measures of al kinds are determined by the Contractor. From the Employer side protective measures are not required. As regards damage caused due to insufficient or incorrect protective measures Contractor will bear the cost of damage rectification. 5.8.2. DEGREASING AND CLEANING Volume i, part # 203 of 246Energy Efficiency by Ecological Coal Quality Management Project C = Procurement and Erection of Equipment for Coal Quality Management Package C#3 - Procurement and Erection of Equiament for a New Stockyard at OCM Tamnava Volume it UPDATED TECHNICAL SPECIFICATION Part 4: MECHANICAL EQUIPMENT. 1B) Contact Documents ers ‘The price of degreasing, cleaning and intermediate cleaning is included inthe Contract forthe respective unit prices. 5.8.3 PATTERNS AND SAFETY MARKING ‘Splits and joints are to be avoided. In case it cannot be excluded Contractor is responsible for the technical co- ordination with the site supervision of EPS prior to the beginning of the coating work on the last protective coating. The price is included in the respective unit prices for coatings, The scope of performance with regard to safety marking (black-yellow) is to be determined in dependence on the constructional arrangement. 5.84 DisPOsAL ‘The Employer proceeds from the assumption that the waste arising from the entire work on corrosion protection is disposed on verifiable and in a proper and workmanlike manner in correspondence with the applicable legal regulations and that the cost thereof is included in the respective unit prices. Volume 1, par 4 204 of 246 f LD