THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R.

VIETNAM

V - PERFORMANCE GUARANTEES AND TESTS

SUMMARY
V - PERFORMANCE GUARANTEES AND TESTS V.A. Warranty for material and workmanship
V.A.1. General warranty period V.A.2. Conditions and effects of the warranty

1 2
2 2

V.B. Performance guarantees

V.B.1. Guarantee figures V.B.2. Notes and remarks on guaranteEd performance values V.B.3. Equipment included in guaranteed power consumption

3
3 6 7

V.C. Test procedures

V.C.1. Running tests V.C.2. Performance test

8
8 9

Contract Vinaincon - FCB.Ciment - 2005

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THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

V.A. WARRANTY FOR MATERIAL AND WORKMANSHIP

V.A.1. GENERAL WARRANTY PERIOD The Guarantee Period shall be twelve months from the date of General Acceptance, or at the latest forty six months from the Effective Date of the Contract. V.A.2. CONDITIONS AND EFFECTS OF THE WARRANTY The following are excluded from the warranty: Defects due to transport, storage, erection, commissioning, operation not performed in accordance with Seller instructions. Damages due to wear and tear except otherwise expressly agreed. Parts exposed to direct fire. Faulty or careless operation. Alterations to equipment made without written consent of the Seller Damages to items not supplied by the Seller, or damages occurred to Equipment due to faulty items not supplied by the Seller. In case of defects on equipment or part of equipment during the Guarantee Period, the equipment or the part of equipment shall be repaired or replaced at Seller option, in conformity with the original equipment or part of equipment. In case of defects during a so-called "pro rata temporis" period, the cost of repair or replacement shall be shared between the Buyer and the Seller proportionally to the time elapsed since the beginning of the Guarantee Period. Any part of equipment repaired or replaced under this warranty option shall be supplied on the same terms and conditions as specified in the Main Terms and Conditions of the Contract. The Guarantee Period for a replacement or a repaired part of equipment shall be as specified in the Main Terms and Conditions of the Contract. If a test is not made for any reason out of the Seller responsibility, the test would be considered as realised and the performances obtained.

Contract Vinaincon - FCB.Ciment - 2005

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THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

V.B. PERFORMANCE GUARANTEES

V.B.1. GUARANTEE FIGURES The Guarantee figures are as follows: EQUIPMENT WARRANTY CONTENT Limestone and shale Crusher Lifetime of blow bars > 5000 h or 2 years Capacity Grain size at outlet Power consumption Lifetime of impact liners FIGURES 950 t/h 95% < 70 mm 1.3 kW/t > 8,000 h PRECONDITIONS - Limestone: - Lump size at inlet < 1500 x 1000 x 750 mm (LxWxH) - Moisture 5 % - Compressive strength < 1100 kg/cm2 - Average SiO2 < 1% - Maximum SiO2 < 4.19% - Shale: - Lump size at inlet < 800 x 500 x 375 mm (LxWxH) - Average moisture 18.6 % - Compressive strength < 600 kg/cm2 - Average SiO2 64% Lump size at inlet < 300 x 300 x 300 mm (LxWxH) for gypsum & pouzzolan Lump size at inlet < 800 x 800 x 800 mm (LxWxH) for limestone Moisture 5 % If CaCO3 standard deviation 20 at inlet If CaCO3 standard deviation < 20 at inlet

Gypsum, pouzzolan & Limestone Crusher

Capacity Grain size at outlet for Gypsum and pouzzolan Power consumption Lifetime of impact liners Lifetime of blow bars Blending ratio CaCO3 standard deviation Reclaimer capacity

200 t/h 95% 30 mm 1.3 kWh/t > 8000 h > 5000 h or 2 years 10:1 2 320 t/h 5:1 1 140 t/h

Raw Mix storage

Coal storage -

Blending ratio Ash standard deviation Reclaimer capacity

If ashes standard deviation 5 at inlet If ash standard deviation < 5 at inlet

Contract Vinaincon - FCB.Ciment - 2005

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THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

EQUIPMENT WARRANTY CONTENT Capacity Finished product fineness Product moisture

FIGURES 320 t/h 10% R90 0.5% 13.0 kWh/t (FCB Index 8.6 kWh/t) 13.9 kWh/t (FCB Index 10.3 kWh/t) > 20,000 h > 20,000 h 10:1 0.2

PRECONDITIONS FCB Index 10.3 kWh/t Free silica content < 2%

Raw mill

Power consumption

Lifetime of roller lining Lifetime of grinding table CaCO3 Blending ratio CaCO3 standard deviation Capacity Calcination rate at kiln inlet Average free lime content in clinker Power consumption Specific heat consumption Specific heat consumption Clinker temperature at outlet Cooler efficiency

Raw meal blending silo

Rotary kiln Grate cooler -

4,000 t/d 92 % 1.0 % 20.8 kWh/t 730 kcal/kgCk 740 kcal/kgCk 65C + ambient 73 %

If CaCO3 standard deviation 2 at inlet If CaCO3 standard deviation < 2 at inlet Silo filling 60% Clinker Cpc50 according to TCVN 7024:2002 LSF < 96 MS(n) < 2.8 A/F(p) < 1.7

Fuel: Quang Ninh coal 4A Fuel: Nui Hong coal 4A Clinker Cpc50 according to TCVN 7024:2002

Cooling air consumption 2.1 Nm3/kgCk Lifetime of grates on > 18,000 h or 2 inlet static module years > 16,000 h or 2 Lifetime of other grates years Lifetime of hammer > 8,000 h or 1 crusher year

Contract Vinaincon - FCB.Ciment - 2005

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THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

EQUIPMENT WARRANTY CONTENT FIGURES PRECONDITIONS - Dust content in ESP and 50 mg/Nm3 bag filter exhaust gas Dedusting equipment > 16,000 h or 2 - Lifetime of filtering bag years - Cement PCB40 - Capacity 240 t/h - Clinker modulus are in the - Finished product fineness 3,000 Blaine same range as specified in appendix I - Power consumption 23.3 kWh/t - FCB-index 24.4 kWh/t - Cement temperature at 80 C silo inlet Cement mill - Lifetime of Shell liners > 16,000 h - Abrasivity-index 81 Coal mill Packing Lifetime of Roller sleeve Lifetime of Shell liners Lifetime of Roller sleeve Product fineness Lifetime of roller lining Lifetime of grinding table Capacity for HGI 43 Capacity for HGI 50 Power consumption Capacity of packer Capacity of truck loader of bag cement Power consumption Tolerance on cement bag weight Lifetime of lining of pan Lifetime of chain Lifetime of chain Lifetime of belt Lifetime of bucket Capacity > 8,000 h > 18,000 h > 9,000 h < 4% R90 > 14,000 h > 14,000 h 27 t/h 30 t/h 39.4 kWh/t 100 t/h 100 t/h 1 kWh/t 200 g/bag > 25,000 h > 25,000 h > 20,000 h > 20,000 h > 30,000 h 150 t/h Quang Ninh coal 4A Abrasivity-index 37

Clinker pan conveyor Bucket elevator Cement Bulk loader Belt weighfeeders

Measuring accuracy

0.5%

Control accuracy 0.5

Contract Vinaincon - FCB.Ciment - 2005

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THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

V.B.2. NOTES AND REMARKS ON GUARANTEED PERFORMANCE VALUES ! Notes on energy consumption and capacities: The energy consumption and capacities of main equipment (grinding mills, burning line) have been estimated, using data coming from samples provided to the Seller at bidding stage or, when not provided, on Seller experience. Should the raw materials used in the plant at the time of performance test appear different than those tested, then the actual performances of the plant could be significantly different from the forecasted values. In such case, a new laboratory with new representative test samples taken during performance test shall be performed, using same procedure as the one used for bidding. The electrical consumption figures specified are calculated at motor terminals The energy consumption and capacities are based on material properties as defined in the appendix I. If needed, a correction could be applied to measured figures. ! Notes on process guarantee figures The process guarantee figures are average values during the test duration. All raw materials must be in keeping with the description made in Appendix I. ! Notes on lifetime guarantee figures: The lifetime specified in this chapter are guaranteed on a "pro rata temporis" basis proportionally to the time elapsed since the starting date of equipment. The lifetime are valid if regular inspection and maintenance is made according to instructions from the sub-supplier. This maintenance can include some cleaning, planed repair, or re-welding, (for instance: cleaning and hardfacing of crusher tooth, reversal of impact crusher blow bars, ). When both lifetime in hours and in years are specified, it is the shortest period which valid the guarantee whichever come the earliest. Lifetime guarantee figures are based on material properties as defined in the appendix I. ! Notes on cooler efficiency: The cooling efficiency is defined as follow: Secondary air enthalpy + Tertiary air enthalpy Clinker enthalpy at kiln outlet Reference temperature: 0C ! Notes on calcination rate: The calcination rate indicated above is a parameter of operation which can varies during performance test. It is guaranteed that this rate can be obtained, but it is not associated to performance test result. In other words, it is not necessary to keep the calcination rate above 92% during all the performance test duration.

Contract Vinaincon - FCB.Ciment - 2005

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Note on packing accuracy Tolerance on cement bag weight is calculated as average value on 10 consecutive 50 kg bags

Notes on blending ratio: The blending ratio is defined as the ratio between standard deviation at inlet and the standard deviation at outlet.

V.B.3. EQUIPMENT INCLUDED IN GUARANTEED POWER CONSUMPTION N 1. 3. 4. 6. Department Limestone & shale crusher Gypsum crusher Raw mill Kiln department Name of equipment Apron feeders 111-AC1 & 111-AC2, crusher 111-CR1, belt conveyor 111-BC1, filter fan 111-FN1 Apron feeder 212-AC1, crusher 212-CR1, belt conveyor 212-BC1, filter fan 212-FN1 Feed valve 312-FV1, mill drive & separator 312-RM1, bucket elevator 312-BE1, mill fan 312-FN2 Kiln I.D fan 411-FN6, kiln main drive 412-KL1, clinker cooler drive 413-GQ1, cooling fans 413-FN1 to FNC, clinker crusher 413-HC1, primary air fans 411-FN3 & 412FN1 and cooler exhaust fan 413-FNE Feeder 415-RF1, roller mill main drive and separator 415RM1, mill fan 415-FN2 Horomill 512-HR1 & 512-HR2, bucket elevators 512-BE1 & 512-BE2, separator 512-DY1, fan 512-FN1 From bucket elevator 612-BE1 to truck-loading stations 612-LT1/LT2

7. 8. 9.

Coal mill Cement mill Packing plant

Contract Vinaincon - FCB.Ciment - 2005

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THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

V.C. TEST PROCEDURES

V.C.1. RUNNING TESTS After erection, the Buyer and the Seller shall carry out the running tests of equipment through following steps: 1. No-load tests No-load test for each separate equipment Consequent no-load test for each group of equipment (in each production section) Technical requirements and procedure of no-load test shall be performed in accordance with operation instructions and technical procedure given by the Seller. The result of no-load test shall be recorded in the report and signed by both parties.

2. On-load tests After completion of no-load test as above mentioned, the on-load tests for each separate equipment and group of equipment shall be performed without any delay in following three steps: First step : 1 - 3 shifts, 8 hours continuous/shift Second step : 1 - 3 days, 24 hours continuous/day Third step : 7 days continuous to reach guaranteed capacity

Contract Vinaincon - FCB.Ciment - 2005

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THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

V.C.2. PERFORMANCE TEST

V.C.2.1. Duration and interruptions for performance warranty test

After completion of on-load tests, if the equipment operates stably, the performance test shall be performed as follows: Duration Number of each of tests test (hour) 8 12 12 24 72 8 12 2 Interruption Max n ofMax duration of interruption interruption per test per test (minute) 1 15 1 1 0 3 1 1 0 15 15 0 60 15 15 0

Department

Limestone, shale, additives crushing 2 Limestone, shale, coal, preblending 2 Raw mill Raw meal blending silo Coal mill Cement mill Packing and cement loading 2 2 2 2 2

Rotary kiln and clinker cooler system 1

V.C.2.2. Accuracies and measuring tolerances

1. All control panel instruments are designed to be accurate 0.5% at full scale. Instruments such as kWh/kVAR instruments to be accurate 0.5% at full scale. All weighers are designed to be accurate 0.5% at full scale, and weighbridges are designed to be accurate within the range of 0.5%. 2. a. b. c. d. e. f. g. h. i. j. k. Measuring tolerances 0.5% for quantities weighed 0.5% for power consumption 1% for measured consumption of heat energy 5 C for measured clinker temperature 0.5% absolute for determination of fineness on the 90 micron sieve for raw meal 1% absolute for determination of fineness on the 90 micron sieve for coal 0.2% absolute for determination of moisture content 30 cm/g absolute for determination of Blaine fineness 5 kg/cm absolute for determination of cement strength 5% on determination of dust emission 0.5% for clinker weighed.

Contract Vinaincon - FCB.Ciment - 2005

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THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

V.C.2.3. Test conditions

Procedures of the tests will be discussed in detail and agreed upon between the Buyer and the Seller prior to commencement of such tests. If the stoppage of machines does not reach the above-mentioned requirements, then the Seller and the Buyer must repeat performance test of the department in total, or the test shall be continued till a duration obeying the conditions above defined is reached. The performance guarantee tests shall be performed, at the Seller's choice, individually for each concerned department or simultaneously for 2 or more departments as the case may be. When several guaranteed figures pertaining to one department are to be attained, they shall be all checked during the test.
V.C.2.4. Measurement methods

Raw meal fineness Each hour the raw meal fineness will be measured by dry screening (Alpine air jet sieving analysis EN196-6). Cement fineness Each hour cement fineness will measured with manual Blaine apparatus according to EN standard. Capacity The production capacities of the various equipment will be determined continuously by means of the weighing equipment of the department, after a calibration using trucks and a weighbridge for specific timed periods. The production capacities of crushers will be determined using trucks and a weighbridge. The clinker production capacity may be determined using trucks and a weighbridge over the total test period. For the clinker capacity, if the continuous measurement method is used, the ratio between meal input measured flow rate and clinker output flow rate shall be established during the performance test by direct weighing of the clinker output over a 24 hour period, using trucks and the weighbridge of the plant. The clinker production over the period without trucks weighing shall be calculated from total meal feed, using the above ratio. Production value will be calculated as an average over the effective duration of the test, excluding interruptions and resumption times Ambient temperature By means of a thermometer installed near a clinker cooler fan intake.
Contract Vinaincon - FCB.Ciment - 2005 Appendix V page 10/12

THAI NGUYEN CEMENT PLANT THAI NGUYEN PROVINCE S.R. VIETNAM

Silo blending effect Each hour, one sample will be taken at silo inlet (feed) and one sample at silo outlet during the silo test, with a time difference taking into account the retention time in the silo. The CaO content will be measured from X-ray spectrometer. Calculation method either for inlet or outlet:

S=

(x
n

X )2

n 1

and

M =

2 2 S IN S LAB 2 2 S OUT S LAB

with S M xi X n SIN SOUT SLAB : : : : : : : : Standard deviation Blending effect Measured values Average value for n samples Number of samples Deviation at input Deviation at output Deviation for sampling and analyzing error

From studies done by the VDI, it was demonstrated that the standard deviation of the sampling process is equivalent to that of the preparation and analysis process. It shall be considered that :
s LAB = s 2 ( sampling )+s 2 ( preparatio n&analysis ) = 2 s 2 ( preparatio n&analysis )

The value for s (preparation & analysis) shall be evaluated directly by producing successively 10 analysis samples from the same basic sample, and determining its composition. It shall be calculated according to the above formula. Preblending pile effect The target is to sample the complete pile: During stacking operation, 36 samples will be taken on inlet belt conveyor at regular times During reclaiming operation, 36 samples will be taken on outlet belt conveyor at regular time. Each sample reclaimed is composed by a mix of 5 primary samples taken during one travel length of the reclaimer. (approx 8 min. for shale and 55 min. for coal) Calculation are based on same principles as above for silo. Free CaO Each hour the free lime content shall be measured by glycol ethylene method or by an appropriately calibrated X-ray system.

Contract Vinaincon - FCB.Ciment - 2005

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Clinker temperature The samples will be taken close after the clinker cooler crusher discharge. Each hour, one sample is and put in a covered, cube shaped metallic box. The box is 0.3 0.3 0.3 m, and is insulated with at least 20 mm rockwool. Clinker lumps issued from crushed blocks after a coating fall are removed by screening at 25 mm. One thermometer or thermocouple is placed in the clinker, at about 5 cm off the bottom. The measured temperature is observed vs. time, and its value is recorded after stabilisation. Power consumption The power consumption of the respective departments will be measured in electrical substation by temporary electrical meters on MCC side for LV motors and by electrical meters of MV cells for MV motors, with deduction of all electrical losses between motor electrical terminals and point of measurement. Such losses will be considered equal to 2%. Power consumption value will be calculated as an average over the effective duration of the test, excluding interruptions and resumption times. Fuel consumption The coal consumption by the calibrated weighfeeder for coal. Correction for moisture content shall be made when necessary. The heat value of the fuel will be determined by a neutral authority of the Buyer's choice, three times during the test period of the respective department. The Seller shall be provided with same samples, for control purpose.

Contract Vinaincon - FCB.Ciment - 2005

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