cc-341- rutenberg power station

THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B"

Engineering Division SPEC.: BZC-2100-34

ISSUE: For Proposal

DATE: July, 2015

BZC-2100-34 rev 2015 07 05 B - 1

SPECIFICATION FOR

SCR SYSTEM - STRUCTURAL STEEL FABRICATION

FOR RUTENBERG POWER STATION - UNITS 3 and 4

1. PURCHASER: The Israel Electric Corporation Limited.

2. NAME OF PROJECT: Emissions Control in existing coal fired

Power Stations.

3. LOCATION OF PROJECT: Rutenberg Power Station, Near Ashkelon

on the Mediterranean Sea Shore.

4. SCOPE OF WORK:

The scope of work includes fabrication and supply of steel structure and on-site

erection supervision services for the steel structure supporting the SCR system

including of Rutenberg Units 3 and 4, which is required as an integral part of the

emission control project (installation of SCR System) in Rutenberg Power

Station.

The scope of work shall include, but shall not be limited to the following:

4.1 Scope of Supply:

Contractor’s scope of supply shall include fabrication (including material and

corrosion protection) and delivery of structural steel and cladding in categories

for Rutenberg Power Station, Units 3 and 4, based on conceptual design and

complete set of structural workshop, parts lists and erection drawings provided

by Purchaser, as follows:

4.1.1 Basic scope of supply, subdivided as follows:

a. Steel structure and legs holding the reactor and the reactor’s inlet /

outlet ducts.

b. Reserved. Approved By: Gideon Israeli

THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: BZC-2100-34 ISSUE: for Proposal

BZC-2100-34 rev 2015 07 05 B - 2

c. Reserved.

d. Steel structure for modifications in the existing boiler steel structure.

The estimated Structural Steel weights for all above structures are given in the

breakdown in Annexure “C1”, which is subject to additions/deletions per

Purchaser’s provided final conceptual design and shop drawings.

4.1.2 The Categories of Steel and works forming part of the scope of work:

(Hebrew translation)

a. Light Shapes and Plates ( יםקל ופלטות יםפרופיל )

b. Medium Shapes and Plates (יםבינוני ופלטות יםפרופיל)

c. Heavy Shapes and Plates ( יםכבדופלטות יםפרופיל)

d. Trusses מסבכים) )

e. Girders (קורות פחים)

f. Base Plates )פלטות בסיס)

g. Grating + Checker Plates ( ומשטחים סבכות)

h. Handrails (מעקות)

i. Stair treads (מדרגות)

j. Bolts, Nuts and Washers (ברגים אומים ודסקיות)

k. Sag Rods (מותחנים)

l. Welded box sections )קופסאות מרותכות(

m. Reserved

n. Painting and Delivery )צביעה ואספקה)

o. Galvanizing, Painting and Delivery )גילוון, צביעה ואספקה)

4.1.3 The Scope of Work includes:

4.1.3.1 Reserved.

4.1.3.2 Reserved.

4.1.3.3 Fabrication of the structural steel members as set forth herein in accordance

with DIN18800.

4.1.3.4 The fabrication contains everything that belongs to the normal execution

according to the designs and parts lists. The scope of supply contains also the

supply of all material, the manufacturing, assembly, quality testing, cleaning as

well as the quality documentation.


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For the avoidance of doubt, all materials such as structural steel, filler materials,

operating supplies, equipment, inspection equipment, packing material,

materials for devices, templates and supports, which can be processed, are in

the scope of supply of the Contractor.

4.1.3.5 If because of delivery constraints of the basic material there is a need for on Site

works for making complementary joints of steel elements to comply with the

fabrication requirements, such works have to be coordinated and approved by

the Purchaser.

4.1.4 The structural steel shall meet the following essential requirements:

4.1.4.1 Low Hydrogen welding processes to be applied in production are:

a. Submerged Arc Welding (SAW).

b. Shielded Metal Arc Welding (SMAW).

c. Flux Cored Arc Welding (FCAW).

4.1.4.2 The Structural Steel including protective coatings shall meet Purchaser’s

provided conceptual and detail design and shall be fabricated and supplied to

form a COMPLETE, RELIABLE AND SAFE CONSTRUCTION.

4.1.4.3 High Strength Bolts, Nuts and Washers shall be EN/ DIN Standard, shall be hot

dip galvanized and shall be supplied by the Contractor in accordance with

Purchaser’s Bills of Materials (specifying lengths, locations and quantities

(100%)) plus 20% spare.

4.1.4.4 All Structural Steel Members shall be corrosion protected as per 11.5 below.

4.1.4.5 The structural steel members shall be fabricated and supplied in accordance

with DIN18800.

4.1.4.6 The elements shall be delivered to the Site in accordance with the delivery

schedule, properly matching and pre mounted in the factory to the largest extent

possible.


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4.1.4.7 Subject to Purchaser's approval (not to be unreasonably withheld):

To simplify manufacturing processes Contractor may replace S275J0+N material

to S275J0+M material and /or to the higher graded S355 J2+N and/or S355

J2+M material.

Similarly, with respect to the S355 J2+N material, Contractor may replace said

material to S355 J2+M material.

Similarly, with respect to the S275 material, Contractor may replace said material

to S355 material.

Filler plates up to thickness 5 mm can be produced from material S235 or S275.

Steel that has requirement for Z15 can be provided in Z25 state.

For handrails, the Material S275J0H can be used.

4.2 Special Equipment, Tools and Instruments

Contractor shall provide all special equipment, tools and instruments required for

safe and secure transport of all components from ex works to final destination.

Said equipment, tools, and instruments (if any) should be / are listed in

Contractor's Proposal where it should be / is clearly stated which are provided on

a loan basis and which are included in the Contract Price/Option list.

4.3 Contractor Services

The Contractor shall provide the services of competent advisors to direct

Purchaser's personnel and assure proper, complete and successful erection and

installation of the Steel Structure provided under this Specification.

The services shall be provided as part of the basic Scope of Work or as

Purchaser’s option, at the per diem or lump sum rates, all as stated in the

Summary of Prices and Delivery Schedule, Annexure “C1”. Field personnel

provided by the Contractor shall be capable and qualified to perform the required

duties to the satisfaction of the Purchaser. They shall be vested with authority to

make decisions that could affect the status of the Steel Structure and which are

binding on the Contractor.


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4.4 Work by Others (Facilities and Services to be provided by the Purchaser)

4.4.1 Purchaser shall provide and be responsible for the conceptual design of the

Steel Structure.

Note: In the event that the Contractor is exceptionally requested to provide

conceptual design, such conceptual design shall be prepared under the auspices

of a structural engineer registered in Israel, and shall be certified by him.

4.4.1.1 Purchaser shall provide a complete set of structural steel Shop and Erection

Drawings, and all the documentation as specified in Article 8 below.

4.4.1.2 Purchaser shall provide Material Source lists based on the design drawings.

4.4.2 Purchaser shall provide all the necessary labor force, tools and facilities in order

to erect and install the Steel Structure provided under this Specification, following

Contractor’s instructions and according to Contractor’s plans, procedures and (if

applicable) supervision.

4.5 Terminal Points and Terminal Connections

Contractor shall terminate the Steel Structure provided under this Specification at

the Terminal Points depicted in Purchaser’s provided conceptual and detail

design with the appropriate terminal connections.

5. SUPPLEMENTS:

The following supplements are attached hereto or referenced in Purchaser’s

transmittal list, and their requirements form an integral part of this specification -

to the extent they are consistent and conform with the requirements specifically

set forth herein. In the event of a variance between the requirements of the

Supplements and the particular requirements set forth in the Specification, the

requirements specifically set forth in the Specification shall take precedence. In

the event of inconsistent requirements set forth in the various Supplements, the

Contractor shall consult with the Purchaser to verify which requirement takes

precedence.


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5.1 Purchaser's general documentation, quality assurance and quality control

requirements:

5.1.1 I.E.C. Painting Specification 217-000093-2011:

Specification for inorganic Zinc-Silicate painting

on non-galvanized surfaces.

5.1.2 I.E.C. Spec/Procedure CL-716/1600/99 Issue 5:

Specification for painting on galvanized surfaces

by wet/electrostatic powder painting.

5.1.3 BZM2100-Supplement 5.5.3 rev 02 –

Surface preparation Corrosion Protection and painting

5.1.4 Standard Q-APP-02 – Rev. 4: Appendices for Contracts / Orders

Quality Requirements

5.1.5 N941023-QP--BNG-BM90--00001_Rev01-STATUS_1

Minimum requirements of the Inspection and Test Plan

5.2 Purchaser's conceptual design drawings:

5.2.1 General notes and drawings list [Hold]

5.2.2 Lower level steel structure [Hold]

5.2.3 Middle level steel structure [Hold]

5.2.4 Upper level steel structure [Hold]

5.2.5 SCR-UNIT 3 - 4 assembling part 1 – 4 [Hold – example attached]

5.3 Purchaser's additional requirements:

5.3.1 Source List of Raw Materials (Based on the Design Drawings)

The source list is for information only “Material Report of Steel”.

5.3.1.1 B.O.M. RUTENBERG UNIT 3 SCR Steel structure summarized see

N941023-ELZ-ISL-ZA110-10002

5.3.1.2 B.O.M. RUTENBERG UNIT 4 SCR Steel structure summarized see

N941023-ELZ-ISL-ZA210-20002


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Notes:

1. The mentioned profile dimensions (length) are system lengths and not

cutting lengths.

2. The material list is separated in four phases of construction.

3. The attached drawings/lists are preliminary and do not include

cutting/scrap material.

5.3.2 Purchaser’s Sample drawings (General):

5.3.2.1 N941023-ECS-ISL-BM510-51105

5.3.2.2 N941023-ECS-ISL-BM510-51128

5.3.2.3 N941023-ECS-ISL-BM510-51260

5.3.2.4 N941023-ECS-ISL-BM510-51336

5.3.2.5 N941023-ECS-ISL-BM510-51337

5.3.2.6 N941023-ECS-ISL-BM510-51172B01

5.3.2.7 N941023-ECS-ISL-BM510-51176

5.3.2.8 N941023-ECS-ISL-BM510-51379

5.3.2.9 N941023-ECS-ISL-BM510-51499B01

5.3.2.10 06_sample_typicals

5.3.3 Purchaser’s Sample drawings - Anchoring Details:

5.3.3.1 N941023-ECS-ISL-BM610-61101B01

5.3.3.2 N941023-ECS-ISL-BM610-61101B02

5.3.3.3 N941023-ELZ-ISL-ZA110-10003

5.3.4 Reserved.

5.3.5 Purchaser’s Sample drawings - GA Steel Structure Drawings - SCR:

5.3.5.1 N941023-ECS-ISL-ZA110-11022

5.3.5.2 N941023-ECS-ISL-ZA210-21022

5.3.6 Purchaser’s Sample drawings (steelwork):

5.3.6.1 N941023-ECS-BNG-BM630-66021

5.3.6.2 N941023-ECS-ISL-BM610-61022

5.3.6.3 N941023-ECS-ISL-BM610-61023

5.3.7 Purchaser’s Sample drawings for gratings, platforms, walkways and kick plates:


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5.3.7.1 N941023-ECS-ISL-BM510-51172B01

5.3.7.2 N941023-ECS-ISL-BM510-51176

5.3.7.3 N941023-ECS-ISL-BM510-51379

5.3.7.4 N941023-ECS-ISL-BM510-51499B01

5.3.8 Standard Specification for Data Transmittal. [Hold]

5.4 Purchaser's workshop drawings: [Hold]

5.5 Purchaser's erection drawings: [Hold]

6. STANDARDS AND CODES

6.1 Standards and Codes referenced in this Specification and in the Supplements to

this Specification form an integral part of this Specification - to the extent their

requirements are consistent and conform with the requirements specifically set

forth herein. All such Standards and Codes are to the issue, including all

amendments, supplements, etc., current as of the date of the Contract, unless

indicated otherwise. In the event of a variance between the requirements of the

Standards and Codes and the particular requirements set forth in the

Specification and the supplements, the Contractor shall consult with the

Purchaser to verify which requirement takes precedence.

6.2 The Steel Structure to be provided under this Specification, including all

appurtenances and accessories, shall be fabricated, inspected, tested,

stamped and preserved to the extent indicated in said referenced Standards

and Codes. Where this Specification does not include such reference, The

Steel Structure, or any of its components, shall be fabricated, inspected, tested

and preserved, as applicable, to comply with currently recognized International

and/or Contractor's Standards, whichever are tighter and more restrictive.

6.3 Reserved.

6.4 Reserved.

6.5 Subject to the provisions stated above, the steel structure shall be designed,

manufactured, erected, tested operated and maintained in accordance with the

standards, regulations, directives and publications of the following agencies and

organizations:


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6.5.1 Israeli Standard 918:

Hot Dip Zinc Coating on Steel and Cast Iron Products (In Hebrew).

6.5.2 DIN 18800

6.5.3 DIN EN 1090

6.5.4 ISO 9001

6.5.5 DIN EN 10025 for material S235, S275, S355

6.5.6 DIN EN 10204 – 3.1 material certificate

6.5.7 DIN EN 13920 – C/G

6.5.8 DIN EN ISO 15614-1 (DIN EN 288)

6.5.9 DIN EN ISO 5817-B / 5817-C

6.5.10 DIN EN ISO 12944

6.5.11 DIN 24531

6.5.12 EN ISO 14122

6.5.13 EN ISO 1461

7. QUALITY ASSURANCE AND QUALITY CONTROL

7.1 Without derogating from the provisions of the General Conditions, Contractor's

quality system shall meet the requirements of Purchaser's Standard Q-APP-02-

Rev. 4 "Appendices for Contracts / Orders - Quality Requirements", and of the

minimum requirements of the Inspection and Test Plan, all as further detailed in

Annexure "M" to the Contract.

7.2 The Contractor and the main subcontractors shall be certified to ISO-9001-

2008 by a certification body qualified to EN-45004 levels A or C or otherwise as

may be acceptable to the Purchaser.

7.3 The Contractor shall submit upon request a copy of its Quality Assurance

Manual including Quality Procedures.

7.4 The choice of main subcontractors shall be subject to Purchaser's approval and

the Contractor shall be responsible for assuring that their quality

assurance/quality control programs, including their organizations, procedures,

personnel qualifications, etc., meet Purchaser’s quality requirements.


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7.5 The Contractor may begin with the manufacturing only after written release by

the Purchaser.

8. TECHNICAL DOCUMENTATION

8.1 The Contractor shall submit technical documentation in accordance with the

provisions of Annexure "J" – Documentation Submission Schedule, and as set

forth below:

8.1.1 All documents of the Contractor have to be provided exclusively in English

language and using European representation standards.

8.1.2 The Contractor commits itself to hand over the final documentation completely in

an error free version. The documentation has to be handed over once in paper

(DIN formats) and once electronically (*.pdf).

8.1.3 Reserved.

8.1.4 All conveyed electronical documents have to be handed over in such a way that

reading, printing and an additional treatment is possible, as well as a text excerpt

(„copy and paste“) (e.g.: *.pdf without writing protection, scanned documents:

Optical Character Recognition [OCR]).

8.1.5 Scans have to be avoided, where possible. If a document must become scanned

nevertheless, it must be scanned as *.pdf in color/grey tones (not as pure

black/white).

8.1.6 The documents have to be stored in such a way that they are normally readable

on the screen without subsequent turn (from left to right).

8.1.7 The files have to be named appropriately: Drawings will get the drawing number

as filename, other technical documents will be named with a short text (e.g.:

"QIP_Steel Structure.pdf")

8.1.8 File names over 60 letters and numbers are to be avoided.


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8.1.9 Special characters are not permitted in filenames. Internationally uncommon

letters (e.g.: „ä“, „ü“, „ö“ und „ß“) have to be replaced (e.g.: „ae“).

8.1.10 Each document contains the project name, short text, creator and date as

minimum requirement (cf. title block in drawings).

8.1.11 Revisions in relation to old editions (in drawings and other documents) have to

be marked within the documents (e.g.: Revision clouds with the note of the

revision [e.g.: Rev. A] on drawings, colored marking within other documents). On

drawings the changes have to be listed nearby the title block, on other

documents on the cover page.

8.2 The procedure of handling technical documentation shall be as follows:

8.2.1 The Purchaser shall submit to the Contractor the conceptual design drawings in

a standard file format (AUTOCAD), and as pdf-files.

8.2.2 Reserved.

8.2.3 Reserved.

8.2.4 Reserved.

8.2.5 The Purchaser shall submit to the Contractor the Material lists in English

language as *.pdf and as *.xlsx.

8.2.6 The Purchaser shall submit to the Contractor the workshop drawings, parts lists

and erection drawings in English language as *.pdf and as *.dwg (AUTOCAD

2010). The Contractor shall have to convert the submitted information in

the drawings into production machine programs.

8.3 Hierarchy of technical documents

The subsequent hierarchy listed in descending order is mandatory in the

evaluation of the requirements set forth in the technical documents mentioned in

this Specification:


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1. Israeli Standards, Codes and Norms

2. The technical specification

3. All other documents including without limitation documents, standards and

norms mentioned therein.

The Contractor shall report to the Purchaser of any conflicting requirements

between documents and of any deviation or misunderstanding of the above

mentioned technical documents, standards and codes within 5 working days

after receipt of said documents, and shall hold fabrication until receipt of specific

Purchaser’s instructions.

The Purchaser shall not compensate the Contractor for non conforming

fabrication due to misunderstanding or non-compliance with the above

mentioned documents and the related hierarchy.

8.2.5 Reserved.

8.2.6 Contractor will not start steel fabrication before the receipt of Purchaser's

approval on the shop drawings relevant for the steel to be fabricated.

9. SHIPMENT AND HANDLING OF GOODS AND DOCUMENTATION

The Contractor shall comply with the requirements for Shipment and Handling of

Equipment set forth in Annexure "R" to the Contract and additionally with the

following supplementary requirements:

9.1 All components or accessories shipped detached for field mounting or field

assembly, including those items to be galvanized, shall be suitably marked by

"hard stamp" so that such marking will be clearly visible after galvanizing and/or

painting.

Additionally, material from one elevation shall not be crated or banded with

material from another elevation.


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9.2 Unless specially designated, all Steel Structure and other items shall be

packaged for outdoor storage until erection. Where required by the nature of the

Steel Structure, the Contractor shall furnish and install necessary covers to

protect the Steel Structure from sand, rain, hail, wind, dust and salt spray. Steel

Structure shall be adequately sealed and protected during shipment to prevent

corrosion and entrance of foreign matter. All exposed machined surfaces shall

be protected where required with a suitable antirust compound or covers before

shipment, for shipment and storage until erection.

9.3 Upon release of erection drawing for production, the Purchaser shall produce the

respective Bill of Fabricated Materials (hereinafter BOFM) to enable checking

and identifying of said Fabricated Materials upon receipt on Site.

9.4 Contractor shall verify compliance with respective BOFM and upon shipment, the

Contractor shall attach one set of hard copy and computer disk of the BOFM to

the respective assemblies.

9.5 The Bills of Fabricated Materials shall include at least the following information:

9.5.1 Item number, consistent with the Bill of Fabricated Materials (BOFM).

9.5.2 Number of items.

9.5.3 Contractor's shop order number (if any).

9.5.4 Manufacturer and/or Supplier, if other than Contractors.

9.5.5 Shop Drawing and Erection Drawing number.

9.5.6 Theoretical weight based on approved Shop Drawing.

9.5.7 Indication of the applicable I&T plan chapters, the fabricated materials were

inspected in accordance thereto.

9.5.8 Shipping details.


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9.6 Every delivery shall be accompanied by a Q/A certificate duly signed by the

Contractor’s Q/A certifying that:

a. All components correspond to the defaults

b. Completeness of all demanded quality tests

c. Testing results according to the standards

d. All NCR completed

e. Documentation complete

This certificate has to be sent before delivery with the transmittal notes by copy.

The source document must be a part of the accompanying documents.

9.7 All parts have to be packed and transported in such a way that they arrive at the

place of destination in perfect condition, taking into consideration that it may be

necessary to store them temporarily outside.

9.8 The transport, including loading the elements and necessary loose parts such as

screw connections, transport locks and covers etc. are included in the scope of

supply of the Contractor.

9.9 The components (construction units) have to be stamped as set forth on the

drawings to allow the allocation of the components to the drawings. The letter

size of the numbers and direction marks shall be 20mm at least and they shall

be stamped deep enough to be clearly visible after galvanizing and painting.

9.10 For transport all openings have to be locked weatherproof.

9.11 If it is necessary, all parts must be stored temporarily in an appropriate way free

of charge for the Purchaser.

9.12 Transport damages on the construction or at the corrosion protection have to be

eliminated immediately and are free of charge.

9.13 Two weeks before distribution the transmittal notes have to be sent to the

Purchaser.

9.14 After completion of Work, the Contractor shall submit to the Purchaser, for

reference and verification, all the updated Bills of Materials showing actual

weights of steel delivered to Site.


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10. RESERVED

11. TECHNICAL REQUIREMENTS

11.1 General Definitions:

11.1.1 Structural Steel Categories:

11.1.1.1 Light Shapes and Plates: Sections weighing up to 58 kg/m / Plates weighing up

to/ 80 Kg/sq.m.

11.1.1.2 Medium Shapes and Plates: Sections weighing between 59 to 150 kg/m / Plates

weighing between 80.1 to 200 Kg/sq.m.

11.1.1.3 Heavy Shapes and Plates: Sections weighing over 150 kg/m / Plates weighing

over 200.1 Kg/Sq.m.

11.1.1.4 Trusses.

11.1.1.5 Girders.

11.1.1.6 Base Plates: Plates having thickness from 1 to 8 inches.

11.1.1.7 Grating.

11.1.1.8 Hand Rail.

11.1.1.9 Stair Treads.

11.1.1.10 Bolts, Nuts and Washers.

11.1.1.11 Sag Rods.

11.1.1.12 Welded box sections.

11.1.2 Weights:

11.1.2.1 Structural Steel Estimated Tonnage shall be calculated using the conversion

factor of 1 Kg = 2.20462 Pounds.


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11.1.2.2 Theoretical Weight:

Weight of shapes, sheets, rods, etc. in Metric Tons, shall be in accordance with

DIN 18800, part 1, Annex B, latest edition.

11.1.2.3 Actual Weight of Steel

The actual weight of Raw Material Steel should be the weight calculated for the

profile which appears on the Shipping Documents.

11.1.2.4 Weights forming the basis for Pricing:

11.1.2.4.1 The Weight of the fabricated Structural Steel for invoicing should be the

Theoretical Weight which appears on the Shop Drawings duly approved by the

Purchaser.

11.1.2.4.2 The unit prices stated in the proposal shall be applicable only to the weights of

the parts as set forth in the parts lists provided by Purchaser assuming specific

weight of 7.85 kg/dm³.

11.1.2.4.3 The Purchaser shall not pay for rolling tolerances, cut off and connecting devices

(e.g. screws, rivets, welding seams) (all included in said unit prices).

11.1.2.4.4 The Contract Price shall be adjusted similarly using the same unit prices for

Changes of dimensions / quantities (increase or decrease).

11.2 General requirements and respective undertakings by Contractor and/or

Purchaser:

11.2.1 Fabrication shall commence immediately after receiving final design drawings, in

conformance, as applicable, with Purchaser’s requested priorities, regardless of

shipping schedule.

11.2.2 Reserved.

11.2.3 Reserved.


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11.2.4 Reserved.

11.2.5 Shop drawing shall be provided by Purchaser for all manufactured materials and

shall include all necessary details for manufacturing including detail drawings,

tolerances, welding symbols and the specific Welding Procedure Specification

(WPS) and weld map, etc. The Procedure Qualification Record (PQR) and the

WPS is to be provided by the Contractor for Purchaser’s approval.

11.2.6 Each Shop Drawing shall include the theoretical weight of the fabricated

Structural Steel. The calculation of this weight shall conform to DIN 18800, part

1, Annex B, latest edition.

11.2.7 Erection Drawings shall contain all the necessary details so as to permit

Purchaser to organize erection in an orderly and continuous manner.

Erection Drawings shall also include details as to how parts are to be assembled

(Welded or Bolted), which torques are required for the high tensile bolt tightening

and inspection on Site.

11.2.8 Changes in Design provided by the Purchaser.

11.2.8.1 Without derogating from the provisions of the general Conditions, Annexure “A”,

the Contractor shall be entitled to a Change Order for extra work when changes

are necessary due to Purchaser's updated requirements.

11.2.8.2 To substantiate such Change Order the Contractor shall submit for Purchaser’s

approval a list showing weight, location and reference to shop drawings of

members that are influenced by Purchaser's provided new requirements.

11.3 Raw Materials.

11.3.1 All the raw materials shall be ordered according to DIN 18800.

All steel shall be furnished in the normalized condition.

In order to assure galvanizing quality, the Silicon content of all steels intended for

galvanizing shall either be less than 0.05% or in the range between 0.15% to

0.3%.


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11.3.2 The Contractor shall be responsible for the complete material procurement,

including all welding filler metals and connecting devices such as bolts, nuts,

etc.. Before manufacturing an inspection of incoming goods has to be realized.

11.3.3 With respect to Material S275 or higher:

The material composition has to be zinc galvanizeable.

11.3.4 With respect to Material DIN EN 10025:2004 the following shall be used in

manufacturing:

a. S275J2+N / S275J0

b. S355J2+N

c. S355ML and S355K for baseplates

11.3.5 With respect to Test reports DIN EN 10204 / 3.1

a. With sheet metals over a thickness by 15 mm an inspection for laminar-

type defects has to be implemented according to DIN EN 10160 class

S2/E2.

b. The certifications have to be collected related to orders and related to the

drawings and part lists and submitted to the Purchaser.

11.4 Fabrication.

11.4.1 Welding

11.4.1.1 The approved Welding processes to be applied in production are:

a. Submerged Arc Welding (SAW).

b. Shielded Metal Arc Welding (SMAW).

c. Flux Cored Arc Welding (FCAW).

and all welding consumables shall be of the Low Hydrogen type and shall be

subject to the approval of Purchaser’s Materials Laboratory.

All Preheating and Post Welding Heat Treatment (PWHT) shall be performed by

the Contractor.


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11.4.1.2 The Contractor must possess the necessary verification of suitability in each

case according to DIN 18800 part 7 (11.2008). This is to be submitted to the

Purchaser before beginning of work.

Any other welding process/consumable, if proposed by the Contractor, is subject

to written approval of Purchaser’s Materials Laboratory as a precondition for its

application.

11.4.1.3 All Welding procedures, Welding Operators and Welders must be qualified In

accordance with DIN 18800.

Detailed Welding procedures shall be presented to and approved by Purchaser’s

Materials Laboratory prior to initiation of work.

11.4.1.4 A detailed welding plan is to be submitted to the Purchaser at least 8 weeks

before beginning of manufacturing. This must contain at least:

a. Welding symbol

b. Material Quality

c. Filler material

d. Dimensions of the material

e. Welding method

f. Welding parameter

g. Welding position

h. Quality according to EN 5817

i. Preheating

j. Post Weld Heat treatment (PWHT)

11.4.1.5 The assigned welding methods must be tested by procedure qualifications

(WPQR / WPS).

No prequalified WPS will be accepted for Automatic or Semiautomatic welding

processes.

If requested by Purchaser, Purchaser’s representative(s) shall witness all

qualifications, prior to initiation of work.

Purchaser's approval is conditioned upon verification by Purchaser’s Materials

Laboratory that the Welding Consumables conform to EN 13479 Standards, and


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that the Quality Control procedures implemented during their manufacturing are

adequate.

11.4.1.6 At least one month prior to initiation of Fabrication, the Contractor shall prepare

for Purchaser's review a list containing the names of its Welding personnel and

the type of welding each individual shall perform. Each Welder will be examined

according to the procedures of the Israel Electric Corporation, and approved for

that type of welding.

11.4.1.7 Only welders may be used, who possess a valid welder certification according to

DIN EN 287-1. The valid welder certifications must be present before beginning

of the welding.

11.4.1.8 For the inspection of the welding seams only checkers may be used, who

possess a valid certification according to DIN EN 473.

11.4.1.9 The welding forming part of the manufacturing shall be supervised and verified

by the welding supervisor with respect to the following:

a. Agreement of the welding method with the data in the designs and the

welding plan

b. Welding joint preparation according to the drawing

c. Cleanliness of the welding seam range

d. Adherence to the welding quality

e. Adherence to measures

f. Protection against harmful influences of the weather

g. Quality of the welding filler metal

h. Correct storage and drying process of the welding filler metals

i. Execution from tacking positions, welding and remove from auxiliary iron

j. Rebore from ignition places, which are not over-welded in the course of a

seam

The use by the Contractor of unapproved Welders, or Welders performing Welds

for which they have not been approved is strictly prohibited. Unauthorized

Welders and Welds as described above shall not be accepted. Furthermore,

such welds shall be removed and welded again according to requirements, at no

exrtra cost to Purchaser.


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11.4.1.10 All Preheating and Post Welding Heat Treatment (PWHT) and all the Non

Destructive Tests (NDT) are included in Contractor’s scope of Work and the

respective PWHT/NDT Subcontractor(s) shall be subject to Purchaser’s

approval. All subsequently specified terms shall be in accordance with approved

quality test and inspection plan (N941023-QP--BNG-BM90--00001_Rev01).

11.4.1.11 Examination/inspection of structural steel welds shall be performed in

accordance with the applicable section of Standard EN ISO 17635 – latest

edition.

11.4.1.12 If on drawings or other specifications nothing else is demanded, the DIN 18800

Group C is generally valid according to DIN EN ISO 5817.

11.4.1.13 Examinations according to DIN 18800 part 7 of all welding seams of the steel

structure are to be submitted to the Purchaser including at least a 100% visual

check.

11.4.1.13 The structural steel welds shall be examined by NDT according to the following

methods:

a. Visual Inspection (VT).

Visual Inspection (VT) for cracks and other discontinuities shall be aided

by a magnifying lens of 5X-10X power to discern indications or defects.

Size and contour of welds shall be measured with suitable gauges.

b. Magnetic Particle Inspection (MT).

Magnetic Particle Inspection (MT) of welds shall be performed in

accordance with the requirements of EN ISO 17638 (areas to be

examined shall be free from scale, grease weld spatter, machining marks,

heavy and loose paint and other foreign matter that can affect sensitivity).

c. Radiographic Inspection (RT).

Radiographic Inspection (RT) of welds shall be performed in accordance

with the requirements of PART B, “Radiographic Testing of Groove Welds

in Butt Joints”, of EN 1435 – last edition.


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d. Ultrasonic Inspection (UT)

Ultrasonic Inspection (UT) of welds shall be performed in accordance with

the requirements of EN ISO 17640 – last edition (if any design

requirement exist, all uncoated flat steel products shall be inspected for

internal discontinuities according to EN 10160).

11.4.1.14 Levels of Examination:

The levels of examination of specific welds shall comply with the requirements

set forth below or as specifically stated in the conceptual design drawings.

a. Butt Welds:

The scope of examination shall be 100% visual (VT).

Radiographic (RT) inspection shall be as per the applicable AWS D1.1 –

last edition requirements. Where RT is required but is not practical, MT

and UT of the root pass and the final surface of each weld joint shall be

performed.

Each radiograph shall have the following additional information

permanently included in the image:

- Weld No. (including repair cycle no.)

- Drawing number.

- Contract number.

b. Fillet welds:

Fillet welds shall be examined by 100% visual (VT) and, if so required by

the DIN 18800 or designer – last edition code, by MT and/or UT inspection

of the final surface of each weld joint.

c. Flanges under tensile stresses of butt-welded beams, and flanges of

extended H profiles:

The scope of examination shall be 100% Ultrasonic Test (UT):

11.4.1.14 UT or RT and MT (see also attached QIPs) as set forth in the Group B of the DIN

EN ISO 5817 of all welding seams with load-bearing construction units and site

welding joints have to be performed by Contractor and the reports shall be

submitted to the Purchaser.


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11.4.1.15 Acceptance Requirements:

The acceptance criteria shall be as per the applicable standards.

The Contractor shall provide all records of Non-Destructive Examination,

including radiographic film, to the Purchaser for approval no later than two (2)

days after the examination.

The final interpretation and acceptance of all radiographs of welded joints shall

be subject to Purchaser’s approval.

11.4.2 General Requirements for Fabrication of Steel Intended for Galvanizing:

11.4.2.1 All holes in Structural Steel shall be drilled.

11.4.2.2 All threaded holes shall be protected while galvanizing by means which shall be

approved by Purchaser.

11.4.2.3 Cutting of Structural Steel shall be by flame, plasma, cutting machines or saw.

Shearing of Structural Steel shall be in accordance with the requirements of DIN

18800 part 7 and EN ISO 9013 latest edition.

11.4.2.4 All Welded Joints shall be cleaned free of slag prior to welding.

11.4.2.5 Structural members, having overlapping surfaces that are to be Hot Dip

Galvanized, shall be seal welded on all contacting edges so as to prevent acid

infiltration during cleaning prior to galvanization.

Note: Seal Welding shall be indicated in the drawings.

11.4.2.6 Reserved.

11.4.2.7 Welder's identification: each welder should have a special identification tag. This

tag should be non perishable. For traceability purposes every welder should sign

(by imprinting) his welding works with his identification tag.


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11.4.3 Tolerance in Fabrication

All tolerances in fabrication, dimensions, layouts etc. shall be in accordance with

the approved quality test and inspection plan (N941023-QP--BNG-BM90--

00001_Rev01).

If there are no instructions in the workshop drawings, the tolerances are valid for

welded structures DIN EN 13920, table 1 and 2, grade C for length, angle, form

and position. Further the tolerances for form and position for welded structures

DIN EN 13920, table 3, precision G are valid.

11.5 Corrosion Protection.

11.5.1 General requirements:

11.5.1.1 Structural steel shall be protected against corrosion by Duplex system

(galvanized and painted).

The Purchaser will hand over a corrosion protection plan for the corrosion

protection works including abrasive blast cleaning (SA 2 1/2) to the Contractor.

Therefor the enclosed project guidelines have to be considered. The selected

coating system will be submitted to the Purchaser for release about 8 weeks

before the beginning of the corrosion protection works.

11.5.1.2 Surface areas of the structural steel which have been milled and for which the

milled surfaces are to be retained without coating, shall be protected during

galvanization and/or painting so that they remain without a galvanized or paint

layer. Varnish shall be brushed in mill area.

11.5.1.3 Connection Areas of slip critical joints shall meet the requirements of 3.2.2(c) of

Specification for Structural Joints using EN 14399 – Latest edition.

Connection areas of painted structures shall be masked after priming before the

intermediate and top painting.


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11.5.1.4 In any case, the Contractor shall remove the masking in the shop.

If "No Paint Areas" become soiled or painted, Contractor will remove any foreign

matter at its own expense.

11.5.1.5 Without derogating from the above, all equipment shall be supplied painted with

prime and top coating (final paint), except for stairs, ladders, hand-rails, which

shall be galvanized or painted according to specific requirements as set forth in

the specification.

11.5.2 Painting Systems:

11.5.2.1 The color of the top coat will be decided upon at a later stage, in accordance with

RAL color scale.

The Contractor shall provide the manufacture/s technical data sheet and Material

Safety Data Sheets (MSDS) for all paints provided, or proposed for Purchaser's

approval.

The Contractor shall provide for repairs at Site at no extra cost to Purchaser 5%

of the necessary theoretical color quantity of all coating systems.

11.5.2.2 Hot-dip galvanized structures shall be painted according to I.E.C.

Spec/Procedure CL-716/1600/99 Issue 5 (Supplement 5.1.2 to the

Specification).

11.5.2.3 Surface preparation, corrosion protection, painting and preservation systems

shall be according to supplement 5.1.3 – BZM2100- Surface preparation,

Corrosion Protection and painting specification:

11.5.2.4 Non-Galvanized structures shall be painted according to Specification 217-

000093-2011 (Supplement 5.1.1 to the Specification).

11.5.3 Scope of Galvanization:

11.5.3.1 All Structural Steel Members that can be inserted in a galvanization tube shall be

hot-dip galvanized according to Israeli Standard 918, latest edition (or equivalent

standard, as approved by the Purchaser)


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11.5.3.2 The corrosion protection of all Structural Steel Members that cannot be inserted

in a galvanization tube shall be subject to Purchaser’s approval.

11.5.4 Detailed Galvanization requirements.

11.5.4.1 The Purchaser while preparing the shop drawings shall design the elements to

be galvanized, while considering the peculiarities of the galvanized steel

structure and ensuring that:

a. Holes to drain the excessive liquid zinc are provided.

b. Fillet weld are continuous.

11.5.4.2 The general and detailed conditions for the preparation, galvanization and testing

of the galvanic coating shall be as specified in, and according to Israeli Standard

918, "Hot Dip Zinc Coatings on Steel and Cast Iron Products", latest edition, and

to the following mandatory requirements:

The following points have to be considered during the execution of the

galvanizing of the material S275 / S355:

a. Welding sequence (reducing of the welding stress)

b. Preheating of the parts to 100°C – 120°C

The Contractor shall verify that the zinc bath is compatible with the material.

11.5.4.2.1 All Galvanized Structural Members shall pass 100% visual examination of the

coating quality. Items with defective coatings shall be repaired by Contractor

according to a method approved by the Purchaser.

Non-acceptable defects are: bare spots, flux, rust, rust to welds, brittle areas.

Dripping and sharp edges are non-acceptable if they interfere with the intended

use of the member.

11.5.4.2.2 Galvanized steel members shall be stored with adequate ventilation between

each member: Each member shall be separated from the other by small steel or

galvanized steel spacers. Members shall be stored vertically if possible. If stored

in the horizontal direction, the members shall be tilted at a small angle to the


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horizontal (recommended 5 degrees) so that water cannot accumulate on the

surface.

11.5.4.2.3 Handling of galvanized steel shall be done with care to avoid mechanical

damage to coating.

11.5.4.2.4 Quality Control for Galvanizing

The galvanizer will have a formal and documented quality system, which

includes quality control department.

The quality system shall encompass at least the following items:

a. Calibrated equipment to measure zinc coating thickness.

b. A procedure for identifying, tracing and recording all coated items

including a system for identifying and inspecting status of the galvanized

items, either coated and tested singly or coated and tested as a batch.

c. Procedures or instructions for rejection and acceptance of coating quality.

d. Written limits on the composition of the cleaners, wash solution and zinc

bath and a system for their control and inspection.

e. Written instructions and inspection forms for the acceptability of cleaned

surfaces.

f. Written instructions and inspection forms for the acceptability of visually

inspected surfaces.

g. Procedures and/or Instructions for in process control of the whole

galvanizing process.

h. Written instructions and inspection forms for the acceptability of coatings

which have undergone thickness tests.

i. Temperature control of the bath and calibration of the control instruments.

j. Inspection criteria for the suitability of welded assemblies and sub-

assemblies for galvanizing, and instructions for the Purchaser.


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11.5.4.2.5 Specification for Repair of Defects in Galvanized Coatings

All galvanized parts shall be inspected after cooling to ambient temperature.

After the hot dip galvanizing the parts has to be checked by a crack test. If there

are any cracks, they have to be protocolled and the corrective measures shall be

coordinated with the Purchaser and the structural engineer (BNG).

Rejected parts shall be cleaned and re-coated as follows:

a. Drippings, sharp edges, excess zinc droplets, etc., shall be removed by

means of grinders or any other suitable tool, when their presence

interferes with the intended use of the component.

b. Spots of flux, dirt, soot or other impurities shall be cleaned by wire

brushing.

c. The weld areas of Zinc coated parts which are subsequently welded shall

be cleaned by wire brushing.

d. Scratches and similar linear imperfections shall be cleaned by wire

brushing.

e. Uncoated surfaces are unacceptable, and shall not be repaired.

Contractor shall re-coat such surfaces at no extra cost to Purchaser.

12. Contractor’s contact person and Purchaser’s Project Engineer

The Contractor shall name an experienced single contact person for technical

issues (Contractor’s Project Leader), who shall be responsible for the whole

execution period. The Contractor’s Project Leader shall be the contact person for

handling with the Purchaser’s Project Engineer all aspects of the Contract and

shall be authorized to make obligatory statements and agreements with the

Purchaser. Additionally, the Contractor shall name a representative person as a

substitute to the Contractor’s Project Leader to act on behalf of the Contractor in

case the nominated Contractor’s Project Leader is not available.


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Accordingly [the following shall be filled in at Contract Signature]:

For the Purchaser:

Name Position Telephone /

Cell e-mail

For the Contractor:

Name Position Telephone /

Cell e-mail

All technical correspondence between the Purchaser and Contractor has to be

executed only between the above registered persons and as specifically required

– the structural engineer (BNG).

Any document transmittal, questionnaires, deviations, scheduling etc. is to be

arranged between these two responsible contact persons. All correspondence

has to be strictly in written mode (via e-mail, postage). Verbal agreements must

be validated in written form.

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