Specification NCS-232 for steel towers fabrication B-spec NPS 232.pdf · TOWERS FABRICATION Edition ... - ITP for Overhead lines steel lattice towers ... This specification describes

Israel Electric Corp. Ltd.

Marketing Division

National Network Unit

Overhead Lines Department

Specification NCS 232

FOR TRANSMISSION LATTICE

TOWERS FABRICATION

Edition no.: 2

Issue date: MAY 2017

Page no. :1 of 42

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SPECIFICATION NCS - 232


TOWERS FABRICATION

Prepared by : B. Shomer

Updated by: E. Chen

Checked and approved by : Y. Samoocha

MARCH 2017


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CONTENT

Paragraph Page 1.General 3 2.Threshold conditions 4 3.Documents for the proposal 4 4. Examining the proposals and the bidders 5 5. Material 5 5.1 Structural Steel 6 5.2 Bolts, nuts, spring washers 6 5.3 Manufacturing standards 7 5.4 Material tests 8 6.Fabrication 8 6.1 Cutting 8 6.2 Bending 9 6.3 Punching and drilling 9 6.4 Welding 10 7. Tolerances 11 8 Marking 12 9.Testing after manufacture 12 10.Galvanising 13 11. Packing 14 12. Quality assurance 15 13. Quality control 15

14. Delivery approval conditions 15 15. Service during warranty period 17 16. Time schedule 18 Appendix "A" – Questionnaire for manufacturer 19-20 Appendix "B" - Statement of manufacturing

experience 21

Appendix "C" – Adjustment to the specification

NCS-232 22

Appendix "D" – annexure 1-15 23-40 Appendix "E" – Israel Electric Corporation

(I.E.C.) - ITP for Overhead lines steel lattice towers 41

1. Revisions 42

Appendix "F" – Quality control Q-APP-02 ED.4


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1. General

This specification describes the requirements pertaining to the manufacture of Steel

Transmission Towers.

All materials, details and fabrication shall be in compliance with details on the drawings

and the requirements described hereafter.

Contract clauses mentioned in the specification are:

Price for IEC catalogue numbers of towers, extensions, assembled and

dismantled crossarms according to Annexure 14. The price includes production

(crossarms which are provided assembled, the price includes production,

assembling, bolts, nuts, spring washers) and delivery under the terms of the

tender. Drawings of this section will be sent along with the order to provider,

(Tower structure layout, IEC catalogue no.' and number of drawings – see

Annexure 14 and 15).

The catalogue number may have more than one drawing, in which case it will be

possible to see in tower structure layout drawing.

Price for the production 1 ton for towers, extensions or crossarms (only supplied

dismantled). The price includes production and delivery under the terms of the

tender.

This section is intended for ordering towers, extensions and crossarms whose

consumption is low and their design is similar to the design of towers, extensions

and crossarms in the previous section.

An order under this section will be done by separate sections, each section IEC

order them (each item and its catalogue number and weight) Supplier will handle

any item as in the previous section regarding packing, marking, shipping and etc.

Cost for 1 ton crossarms which are provided assembled. The price includes

production, assembling, bolts, nuts, spring washers, and delivery under the terms

of the tender. Example for crossarm supplied assembled can be seen in annexure

15.

Cost for assembling 1 ton prototype assembly. The price includes assembling, film

the assembly, dismantling, and issue a report.

Changes drawings: IEC permitted from time to time to update the production

drawings, drawings will be sent to supplier, within two weeks supplier shall

reference the change and in accordance with the agreement to reach - will be

carried out.


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The specification describes fabrication procedures such as: cutting, bending, punching,

drilling, welding and bolting, marking, galvanizing according to the shop drawings.

The specification defines requirements for packing (some of the crossarm will be

supplied assembly) and transportation, quality control, shop assembly, and service

during warranty period.

Quality Control requirements will be acc. Q-AAP-02 ED4.

For fabrication procedures not covered in this specification, the latest edition of other

industrial standards shall be applicable.

In case of discrepancies or nonconformity between documents, priority shall be as

follows:

1. The drawings.

2. The present specification or written approval by IEC (Israel Electrical Corp.)

engineers.

3. Other industrial standards.

2. Threshold conditions:

In accordance with the attached documents of the supply and storage division.

3. Documents for the proposal

The bidder will submit together with his offer the following Documents:

3.1 For all the bidders:

3.1.1 Completed and filled-in questionnaire, see appendix A.

3.1.2 Declaration appendix C:

3.1.2.1 Declaration indicating that raw materials - steel and bolts, purchased from

manufacturers (who have Valid ISO 9001 certificates) to be approved after

winning by the IEC.

3.1.2.2 Declaration indicating that the proposal fully meets all requirements

of present specification and fabrication drawings.


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3.1.2.3 Declaration indicating that non Israelis manufacturers will be employing by the

Contract Israeli subcontractor for services as written in para.15 (only for foreign

contractor).

3.2 For bidders that not approved as IEC suppliers for lattice towers fabrication

3.2.1 Valid ISO 9001 certificate as defined in the threshold conditions.

3.2.2 Statement of manufacturing experience, see appendix B.

3.2.3 Manufacturers Fabrication facility description (Brochure, Catalog) of capability

with respect to items in tender.

3.2.4 Manufacturer shall submit Plant organization chart and technical staff

description.

-The above mentioned documents will be in English or Hebrew.

4. Examining the Proposals and the Bidders

IEC representatives shall be entitled to visit any plant, site or office which is held or

operated by the bidder and to request and to receive any information concerning the

bidder and/or the services offered. The IEC shall be entitled to disqualify any proposal if

it deems that the person submitting the proposal did not cooperate with the IEC

representatives or did not furnish information as required.

The purpose of the visit: checking whether a manufacturer can meet the specification

and verification of data filled out the questionnaire.

5. Material


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The Successful Bidder will purchase steels and bolts only from the list of manufacturers

that have Valid ISO 9001 certificates and approved by IEC. The successful bidder can

change steel, bolts, nuts manufacturers with IEC approval.

5.1. Structural steel designation standard

Designation of steel will conform to EN 10025 –part 1,2. (“Steel for General Structural

Purposes”).

The steel will be “suitable for hot galvanizing”.

Steels are to have Si contents less than 0.04% or from 0.14% to 0.25%.

Designation of steel

All items:

According to European standard - EN10025:2004 steel S235JR or S235JO

According to European standard - EN10025:2004 steel S355JO

All materials shall be brand new.

Before being laid or worked in any manner, structural materials shall be straight and

shall be cleaned of all rust and dirt. If straightening is necessary, it shall be done by

methods that will not damage the metal.

5.2 Bolts, nuts, spring washers

Bolts, nuts, spring washers that will be dedicated to crossarms needed assembly.

5.2.1 Bolts

Degree of bolts strength will be 50 kg/mm2

Bolts will be acc. ASTM – A-394, Type 0 – zinc-coated bolts made of low or medium

carbon steel.

Bolts hardness will be Rockwell B Min. 80, Max 100.

Bolts will be hot dip galvanized minimum thickness 40 µm.

Dimensions and tolerances see annexure 13.


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5.2.2 Nuts

Nuts will be acc. ASTM-A 563 GrA.

Material shall be from carbon steel.

Nuts hardness will be Brinell MIN 116, MAX 302. Rockwell MIN B68, MAX C32.

Nuts will be hot dip galvanized minimum thickness 40 µm.

Dimensions and tolerances see annexure 13.

5.2.3 Spring washers

Spring washer will be acc. ASME B18.21.1- 1999.

Material shall be from carbon steel.

Dimensions of Regular helical spring lock washer acc. table 1 in ASME B18.21.1- 1999.

Hardness requirements shall be: HRC 40-50, 392-513 HV.

Spring washers will be hot dip galvanized minimum thickness 40 µm.

5.3 Manufacturing standards - dimensions, shape and tolerances

The dimensions and tolerances of items must conform to the following standards:

5.3.1 Angle Iron

Hot Rolled Round Edge Equal & Unequal Angles - according to, EN 10056-1,2.

5.3.2 Channel Profiles

Hot Rolled Round Edge/Channels - according to, EN 10279.

5.3.3 Flat Profiles and Strips

Hot Rolled Flat Steel for General Purposes 5/10-60/150 - according to DIN 1017 -1 &

EN 10058.

Hot Rolled Wide Plates 5/150-60/1250 - according to DIN 59200.

Hot Rolled Strips, Hot Rolled Sheets 0.8/10-10/120 - according to, EN 10048.

5.3.4 Plates


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Hot Rolled Plates (3 mm to 150 mm thick) - according to, EN 10029

Cold Rolled Plates less than 3 mm thick - according to, EN 10131.

Note: Other raw materials equivalent properties (which are not listed in this

specification) may be proposed for approval by the IEC.

5.4. Materials tests

The successful Bidder (contractor) shall identify all materials on the appropriate mill test

reports and shall furnish them to IEC.

The contractor is required to perform the physical tests on samples of structural steel

sections.

The tests to be carried out shall include yield strength, ultimate tensile strength and

percentage elongation and show chemical properties.

The contractor shall supply test reports for bolts acc. ASTM – A-394, nuts acc. ASTM-

A 563 and spring washers acc. ASME B18.21.1- 1999.

6. Fabrication

Production will be controlled with suitable machines (such as drilling and punching will

be done by CNC machines), appropriate work areas, manpower to carry out the work

will be suitable and competent to perform various works.

During the manufacturing process safety precautions will take according "Standard

Practice for Safeguarding Against Embrittlement of Hot – Dip Galvanized Structural

Steel Products and Procedure for Detecting Embrittlement" – A 143 – Latest edition.

If there is discrepancy, this should be settled in writing prior to fabrication.

6.1 Cutting

Materials may be sheared to length, but the ends, unless otherwise noted, may be square

with the length and free of burrs so that difficulty of assembly caused by the interference

of the end section with other members at the time of assembling the steel tower may not

occur.


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The use of a burning torch is permissible for cutting members providing all irregular

edges are trimmed smoothly before galvanizing. Stresses shall not be transmitted into

the metal through burned surface. The use of a burning torch for cutting bolt holes will

not be allowed.

Materials with thickness of less than 18 mm may be cut with a suitable guillotine on

condition that no distortion is caused.

Materials with thickness of more than 18mm must be cut with a saw or burning torch.

Note: Other method cutting only with the prior approval of the IEC

6.2 Bending

The possibility of cold bending normally depends on the shape of part (angle, plate, etc.),

type of steel, angle and radius of bending and equipment for bending.

The radius of the bend will be not less than 3 times of part thickness.

All bends of a difficult nature on structural steel shall be performed while the material is

hot.

Members bent hot shall be heated in a non-oxidizing flame over a sufficient area to

prevent excessive deformation.

Hot bends shall be placed for slow cooling in air.

All bends shall be finished, free from waves, folds.

A member bent in error with respect to the location of a bend line shall be rejected.

You cannot bend back steel already over-bending flexion.

6.3 Punching and drilling

The manufacturer must carry out the drilling and punching with CNC machines.

Holes are to be punched with racks and jigs employed to ensure accuracy throughout.

The punches and dies for this work must be maintained sufficiently sharp so as to

produce clean round holes.

Holes may be punched and drilled in high-strength structural steel under 11 mm thick.

Over 11 mm holes can be punched to preliminary hole and then be finished by drilling to

final dimension and reamed.

Table no.1 shows the dimensions of preliminary and final holes.

Table no.1

Bolt

Preliminary

hole (mm)

(punching or

drilling)

Final hole

(drilling)

1/2" 10 14.5


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5/8” 14 17.5

3/4” 17 21

7/8” 20 24

1” 23 27

Holes in elements with welded reinforcement plates will be done only after welding.

Thickness of such element will be calculated according the sum of thickness of element

and reinforcement.

Holes in bent members which may be affected by the bending operation shall be laid out

and punched or drilled after bending. Holes which are elongated or otherwise distorted

by bending will not be accepted.

Special care is to be exercised to ensure exact spacing of holes and their distance from

back of angle and to end of piece.

No welding, filling or plugging will be permitted unless otherwise approved by IEC.

Plates can be produced using computerized machines laser or water, provided that plate

edges and holes will be clean and smooth and on condition that would not cause damage.

6.4 Welding

All welding is to be performed in the shop. Welding will be in conformance with the

AWS D1.1 of the American Welding Society Structural Welding Code.

Welding process: SMAW.

Welding quality will be according to AWS D1.1.

Welding symbols will be, acc. ISO 2553, BSN EN 22553, Israel Standard 1061.

All welding shall be performed by qualified welders, or welder operators, using qualified

welding procedures in accordance with the Code AWS D1.1.

Electrodes:

Butt welds - E7018 ASME SFA – 5.1.

Diameter of electrode: 2.5-4.0 mm.

For fillet welds E7024 can be used.

Seal welds up to 3 mm possible to perform – welding process GMAW with CO2 backup

gas.

Type of welds:

Complete penetration groove welds (see annexure).


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- Two angles to back plate connected externally, see ann.1.

- Penetration welds (Angle to plate connection), see ann. 2.

- Internal connection of two angles with angle, see ann.3.

- U Profile connection, see ann. 4.

- Directive for penetration and fillet weld check, see annexure 5.

- Internal connection between two angles by welding a connection angle, see ann.8.

Bevel preparation:

Bevels shall be prepared by grinding or machining, by Arc air gouging or plasma cutting.

After cutting, surface must be ground smooth and must be free of burrs and all oxides.

Bevels shalll be prepared according to the welding details as shown in annexure 1-4.

Types of welds and joints will be according to the drawings otherwise- according to

AWS D1.1.

Testing of welds

The contractor will check the welding visually to make sure it meets the requirements

specified in the standard AWS D1.1:

Measurements, tattoos and overlapping, penetration and melting, cracks, backing strip,

pores and slag, welding final cleaning

Changes in method of welding

In case that contractor wants to make changes in welding procedures he must to receive

a permit of IEC metallurgical.

In addition to the above, the IEC reserves the right to visit the Contractors Works at

any reasonable time during fabrication of the items of plant and to familiarize himself

with the progress made and the quality of the work to date.

In the event of the Contractor wishing to make an alteration to any part of the weld

preparation, he shall first submit to the IEC a copy of the revised drawing showing the

amended preparation in detail and await confirmation of its acceptance or non-

acceptance.

All important welding that, according to the IEC, may be subject to excessive efforts

or do not seem to comply with the standards, may be x-rayed at his request.

7. Tolerances

The parts of tower will be manufactured in accordance with the drawings.


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- Tolerance of the length of each part shall be +2.0/-1 mm for leg part elements and

braces.

- Tolerances for center to center hole spacing will be 1 mm and not gathered.

- Tolerance between center of hole to the end of steel part will be + 2 mm.

- Tolerance to hole diameter will be -0/+0.5 mm

- Tolerance to length and width of plate will be+/- 1 mm.

- Tolerance to bending plates or bars dimension will be +/-1 mm

- Tolerance to weld length dimension will be +/- 1 mm

- Tolerances to hinge connection on crossarms will be -0/+1 mm

- Tolerance to crossarm connection to tower +2/-1 mm

- Tolerance from center of bolts segmentation to end of profile (in external joint) will be

+1/-0 mm, and +0/-0.5 mm (in internal joint)

- Tolerances for center to center hole spacing in braces will be +/- 0.5 mm.

The supplier shall supply a list of fabrication tolerances to the purchaser for approval.

8. Marking

All dismantled tower members are to be stamped with distinguishing numbers or letters

corresponding to the information below. These marks shall be impressed before

galvanizing and are to be clearly readable afterwards.

The following information shall be stamped on each item:

- Trademark of manufacturer

- Type of tower (for example TMH2 T)

- Item number

The height of letters or numbers will be 12 – 20 mm.

The example of marking see annexure 6a.

Bolts marking:

The bolts will be marked according to ASTM-A 394 Type 0 and in addition

manufacturer name or trade mark.

9. Testing after manufacture

9.1 At the end of production before sending to galvanizing, the manufacturer must

check geometric dimensions of the items, location holes, bending angles and

etc.


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All tests should match the requirements of drawings and specification, if there

were discrepancies, required to repair or replace the items.

9.2 The successful Bidder that supply in the past tower types that mentioned in

the tender for IEC is free from prototype assembly.

9.3 For manufacturers that didn't supply the towers for IEC– before first

supply and before galvanizing - A trial assembly of the prototype of each type

of structures, including all body crossarms and all leg extension, shall be made

prior to bulk fabrication to prove accuracy of details and fabrication,

see ann. 10. Assembly will be maid lying in horizontal position plus

supporting as needed.

Remaining of mismatched holes will not be permitted.

A reasonable amount of drifting will be allowed in assembling.

The bolts for shop assembly can be any bolts that fit by diameter and length.

Instruction for steel structure connections with bolts, see ann. 7.

Shop assembled parts shall be dismantled for shipment.

Shop assembly shall be controlled and approved by the I.E.C.

The IEC reserves the right to obtain from any lot of material being fabricated,

sample coupons for independent testing by a IEC laboratory and to reject any

lot of material, for which such tests fail to meet Specification requirements.

10. Galvanizing

Galvanizing plant has a valid ISO 9001 certificate. The certificate shall be valid for hot

deep galvanizing of steel.

Galvanizing will be according to ASTM A123/A 123M-09, or EN ISO 1461:2009.

Except where specified to the contrary all steel used in the construction of towers shall

be galvanized after all sawing, shearing, drilling, punching, filling, bending and

machining is completed. The zinc coating is to be of uniform thickness, clean, smooth

and as free from spangles as possible. Galvanizing shall be applied by the hot deep

process and shall consist of 0.085 mm in thickness for steel more than 8 mm of

thickness and 0.07 mm for steel from 5 to 8 mm thickness.

All holes will be free after galvanizing, min. free hole will be:

14 mm for 1/2 " bolt

17 mm for 5/8 " bolt

20.5 mm for 3/4 " bolt


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23.5 mm for 7/8 " bolt

26.5 mm for 1" bolt.

A manufacturer's Certificate of Inspection for hot–dip galvanized coatings on structural

steel (see annexure 11) shall include the following information:

- Purchase order number

- Date of inspection

- Number of pieces tested for weight of zinc coating with maximum, minimum and

average weights of each.

- Number of pieces tested for adherence of coating

- Number of rejections because of defective coating and other reasons

Certified test reports shall be submit to IEC, see para. 14.

11. Packing

All items of tower will be dismantled except the crossarms for towers, according the

drawings.

All items of each part of tower (Element 1, Element 2, ...) will be placed in separate

bundles according to fabrication drawings (Material packing table). Bundles of steel

angles shall be properly tied together: long items will be placed underneath, small angles

will be above. All bundles will be placed on a wood skeleton platform (consisting of

deck boards and runners) and secured with double 6 mm thick galvanized steel strips at

least in 3 places. Deck board shall have a minimum thickness of 25 mm.

Crossarms will be assembled with bolts, nuts, screw washers acc. the drawings and

ann.7.

The hangers and the vertical diagonals will be tied to a crossarm leg with double 6 mm

thick galvanized steel strips at least in 3 places - ann.15.

Each packing shall contain a packing list with part drawing and circle around each item

that is in the package, see annexure 12. Packing list will be in a waterproof envelope.

All the plates will be packed separately in boxes. The plates will be threaded on

galvanized wire 4 mm thick. An identification tag and box marking will be threaded on

the same wire. There will be a separate tag for each part of the tower. The boxes will be

closed.

Each tag will include the following information:

Name of manufacturer

Country of manufacture


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IEC Catalogue number

Type of tower

Name of part of the tower

List of items marked on drawing

No. of Order

Bundle Weight (kg).

Example of tag see annex.12.

Packing control & tests:

Manufacturer will control the contents of the package. Manufacturer makes sure by tests

that all the items of tower/part are packed and it will not be missing elements in package.

Control processes should be documented and transmit with delivery of goods.

IEC will check in random base content of packages according to the relevant drawing

and attached packing list.

Care must be taken during handling and shipping to avoid damage to the elements and to

galvanization.

Transportation will be via sea and then land transportation - approximately 100 km from

the port to IEC warehouse. Each IEC catalogue item will be separated in such way that it

will be possible to identify it in warehouse.

Contractor will send two copies of packing lists for each shipment to IEC Head Office.

12. Quality assurance

Manufacturer's Quality Assurance Program shall meet the requirements

described in ISO 9001.

13. Quality Control

Quality Control requirements will be according to I.E.C. Standard Q-APP-02 ED.4 and

annex. E.

14. Delivery approval conditions According to the schedule described in Chapter 16


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14.1 The successful bidder will submit list of steel manufacturers and their Valid ISO

9001certificates. The certificate shall be valid for the scope of activities

requested in the request of proposal.

14.2 The successful bidder will submit list of bolts manufacturers and their Valid

ISO 9001certificates. The certificate shall be valid for the scope of activities

requested in the request of proposal.

14.3 The successful bidder will submit welding Procedure Specification WPS and

welding personnel qualification (welders, welding operators, and tack

welders).

14.4 The successful bidder will submit materials tests certificates for IEC approval

in two month from starting point (see para.15) for first delivery and month

before the shipment of each delivery.

IEC approval will take one week.

14.5 In two months from starting point (see time schedule para.15) The successful

Bidder shall propose a Local Subcontractor, who will be responsible for

services written in para.15, for IEC approval.

Documents provided from Local subcontractor:

- Declaration that subcontractor has experience in manufacture of

steel constructions at least for 2 years during 5 last years.

- Documents that prove that the subcontractor has his own equipment for

punching, drilling, cutting and welding.

IEC will check the proposed subcontractor and in one week final

approval will be furnished up to 3 month from starting point.

14.6 The successful bidder will receive IEC approval for shop assembly in one week

up to 3 month from starting point.

14.7 The successful bidder will sent to the IEC before delivery the following test

certificates: Certificates of inspection on welds, test certificates for

fabrication, test certificates for galvanizing and packaging inspection

certificates.


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14.8 If the required prototype assembly, the successful bidder shall schedule and

location of the assembly to IEC, about six weeks before the deadline,

IEC or its representatives shall have the right to be present,

The successful bidder will film the assembly, issue a report and send to the IEC,

the IEC's approval will be possible to dismantling the assembly and send

galvanization.

Acceptance test

The I.E.C. reserves the right to verity the compliance of the delivered items

with this specification.

Delivery which will not pass acceptance test will be rejected.

15. Service during warranty period

In case of defects that can occur, for instance:

- Missing elements

- Manufacture of element is not accurate – tolerances, holes, length, wrong profile

etc.

- Damage from transportation etc.

- Where galvanizing is damaged from any cause, at the option of the IEC, the

damaged steel is to be either re-galvanized or the bare metal to be painted over with at

least two (2) coats of an approved zinc rich paint to afford protection equivalent to

galvanization

The successful Bidder shall provide (by subcontractor or by himself) the following

services: repairing of elements, manufacture of missing or damaged or defective parts.

The Representative of the Bidder in Israel (Local subcontractor) shall be on site within

24 hours of written notification.

New element or repaired one will be supplied within 48 hours.

It will be repaired, at no extra charge.


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16. Time schedule for Materials, Welding procedure and

subcontractor approval

Remarks:

1. Starting point is the date on which a binding contractual obligation has been created,

as specified in the invitation to submit proposal.

2. Total schedule for all procedures up to 3 month from starting point

16151413121110987654321STAGENo.

Submit list of steel manufactures1

IEC approval steel manufacturer2

Submit list of bolts manufactures3

IEC approval of bolst manufacturers4

Submit welding procedure5

IEC approval of welding procedure6

Materials certificates tests7

IEC approval certificates tests8

Propose the Local subcontractor9

IEC approval of subcontractor10

Manufacturer shall inform end prototype assembly11

Prototype shop assembly11

Manufacturer shall inform end prototype assembly12

IEC shop assembly approval13

Week


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Appendix "A " - Questionnaire for manufacturer

Please fill in the questionnaire:

General: _ Manufacturer / Fabricator Name:

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________ Company's Address :

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

____________________________________________________________

Tel no. _____________________________________________________

____________________________________________________________

Email________________________________________________________

____________________________________________________________

web.site_____________________________________________________

____________________________________________________________

FAX________________________________________________________

____________________________________________________________

Contact person _________________________________________________

____________________________________________________________


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1. Requirements from manufacturer

Requirements Required Data offered by

Bidder

1 Statement of manufacturing

experience, see para. 3

required Yes/No

2 List of Automatic/computerized

machinery suitable for cutting

Punching and drilling, see para.6

required Yes/No

3 Quality assurance, see Para. 12 ISO 9001 Yes/No

4 Quality Control System, see

Para.13 required

5 Storage area for shop assembly MIN 1000 sq m for 161 kV

towers

MIN 2000 sq m for 400 kV

towers

6 Storage area size for raw

materials and for finished

production

MIN 1000 sq m

7 Welding equipment description

required

8 Quantities of Fork – lifts, cranes

required

9 Quantities of Manpower –

technical personnel – engineer

level, and employees for towers

manufacturing.

At least one engineer and

one technician

10 Manufacture capability (tons per

month) MIN 100 ton per month

11 Specify Welding Procedure

Specification WPS qualification required Yes/No


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and the qualification tests by all

welding personnel, see Para. 6

i)

APPENDIX "B": STATEMENT OF MANUFACTURING EXPERIENCE

I, ________________ (enter name), hereby state the following:

1. I_________(enter name) , am authorized to sign this statement on behalf of_________

("the Manufacturer").

2. I hold the position of ____________________ ____________________________ (enter

job title and description, i.e. partner, production manager, sales manager, etc.) at the

Manufacturer.

3. I have been in this position since __________ (enter date).

4. I am providing this statement with regards to I.E.C's tender number ____________ ("the

Tender").

5. The facts/details given in this statement have been checked and verified by me.

6. _________________ The manufacturer factory is active and has at least 2 years (in the

last 5 years) of proven experience for the lattice steel towers manufacturing. Capability

of manufactured steel lattice towers at least - 900 ton per year.

7. _________________ The manufacturer has own or rents CNC machinery suitable for

cutting, punching and drilling for profiles and plates.

I hereby undertake to provide, upon IEC's request and at its sole discretion, any

Other documents (reference list, quantity, dates of supply, letter of

Recommendations etc.), or other Information requested for this tender for

purposes of proving said experience.

_______________

Signature

_______________

Date


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Appendix "C " - ADJUSTMENT TO THE SPECIFICATION NCS-232

OBLIGATION

1. We ………………………………………………., hereby declare that the

proposal fully meets all requirements of present specification and fabrication

drawings.

2. We ………………………………………………., hereby declare that raw

materials - steel and bolts, purchased from manufacturers (who have Valid

ISO 9001 certificates) to be approved after winning by the IEC.

3. We ………………………………………………., hereby declare that we will

employ by the Contract Israeli subcontractor for services as written in para.14

(only for Foreign contractor), in case of winning the tender.

Signed: __________________________________________________

Name: ____________________________________________________

Duly authorized to sign this Obligation: __________________________

Dated on ____________________________________________________


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Appendix "D" – annexure 1-15 (without 9)


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Annex No. 11 – Hot plating of Zinc, Process control Objective

The purpose of this annex is to define the means of control and treatment of parts that go

through Zinc coating, in order to guarantee final product quality and reliability within a

corrosive environment.

1. General

In order to guarantee adequate control of the process it is necessary to establish a

quality control system and document all stages of the process with regards to each

batch of parts that undergo the coating. The contractor shall appoint a trustee, whom

is responsible for the maintenance of the system described above and in addition shall

document all activity aimed at guaranteeing final product quality, delivered to IEC as

described below.

2. Process Control

The manufacturer shall submit to IEC quality control full documentation with regards

to all the process stages. The documentation shall include the following information

regarding each process stage:

A. Type and concentration of materials as well as measurement method and control.

B. Process temperature and means of measurement.

C. Process duration and means of measurement.

D. Criteria which define adequate completion of any given process stage and its

progress towards subsequent treatment.

E. Production line maintenance procedures: methods of inspection, concentration

levels of active material components and documentation of the findings, frequency of

inspection\monitors, documentation of introduction of materials to the bath etc.

3. Documentation

3.1 Documentation shall be performed by means of a "route card", located within

proximity to the batch and associated with each and every stage of the process: clean,

rinse and flux, dry, soak in Zinc, cool, etc. Matching between identification/marking

of a given batch and the corresponding documentation must be ensured.

3.2 A contractor representative shall provide his/her signature indicating proper and

completion of the specific process stage.

3.3 The signed certificates shall be submitted to IEC quality control prior to delivery

of the batch for approval.


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4. Final Inspection

4.1 The manufacturer shall establish and document criteria, based upon relevant and

approved standards (such as Israeli standard 918, 265 etc.), in order to enable

acceptance\rejection of the final product.

4.2 Inspected products shall be marked or labeled as "approved", "further processing

required" etc. The label must include the date, batch number and a distinct signature

of the inspector.

4.3 Corrective action – the manufacturer shall establish procedures for corrective

action in the event of defects revealed during inspection of the final product,

including root cause identification, means of fixing the defect, approval and

documentation.


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Annexure 13


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Annexure 14

Tower Type IEC Ca. No.' Description Drawing No.' MSR2G --- Tower structure layout NCD6320_EN

5227199 Standard tower without head NCD6320_EN including NCD6321_EN,

NCD6322_EN, NCD6323_EN ,NCD6324_EN,

NCD6325_EN

5227310 Head 3.0m NCD6735_EN

5270120 Head 4.5m NCD6331_EN

5227350 Extension No.'1 3m NCD6326_EN



5227347 Extension No'.2 6m NCD6329_EN


5253427 Upper extension 3m NCD7991_EN

4132700 Upper middle and lower

unindependant crossarm 4.2m

NCD3366_EN

5253452 Unindependant crossarm for

earthwire 2.6m

NCD7992_EN

MMSH2 --- Tower structure layout NCD3355_EN

5267716 Tower without head NCD3355_EN including JDHK3357_EN,

JDHK3358_EN, JDHK3359_EN

,JDHK3360_EN, JDHK3361_EN

4137337 Head 3m NCD3356_EN





4132791 Tow-sides asymmetric

crossarm 3.75+4.65m

NCD3365_EN



NCD3366_EN


earthwire 2.6m

NCD7992_EN

TMH2G --- Tower structure layout NCD5160_EN

5000546 Tower without head NCD5160_EN including NCD5161_EN,


NCD5165_EN

4513255 Head 3.0m NCD4845_EN

4513263 Head 6.5m NCD4844_EN



earthwire 2.6m

NCD7966_EN




5011383 Extension No'.2 6m NCD5169_EN

5273847 Straight extension 3m NCD8851_EN



NCD3399_EN


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Tower Type IEC Ca. No.' Description Drawing No.'

TMH2T --- Tower structure layout NCD3437_EN



NCD3420_EN

4513255 Head 3.0m NCD4845_EN

4513263 Head 6.5m NCD4844_EN





unindependant crossarm 5m

NCD3406_EN


earthwire 3.4m

NCD7967_EN


earthwire 2.6m

NCD7966_EN

TMC2G --- Tower structure layout JDHK9080_EN

3549920 Standard tower without head JDHK9080_EN including JDHK9081_EN,

JDHK9082_EN, JDHK9083_EN ,JDHK9084_EN,


5269111 Head 6 m JDHK9089_EN

3166519 Extension 3m JDHK9085_EN


3663036 Upper and lower


JDHK9087_EN

3663044 Middle unindependant

crossarm 4.5m

JDHK9088_EN

Branching

tower

TMH2T

--- Tower structure layout NCD7795_EN



NCD3420_EN


5255202 Head 6.5 m NCD7772_EN

5255200 Head 3 m NCD8070_EN

5255201 Head 1.6 m NCD8071_EN



NCD3406_EN

5255584 Upper middle and lower one

dide crossarm 5m

NCD8080_EN



earthwire 3.4m

NCD7967_EN

5256563 Additional steel to connect

one side crossarm

NCD8127_EN

2487585 Branching plates JDHK8981_EN

4162079 Extension 3m NCD3421_EN



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Tower Type IEC Ca. No.' Description Drawing No.' TMH2T air

terminal with

termination in

20º inclined


5268679 Standard tower without head NCD7900_EN including

NCD7901_EN, NCD7902_EN,

NCD7903_EN ,NCD7904_EN,

NCD7905_EN

4513255 Head 3.0m NCD4845_EN

4513263 Head 6.5m NCD4844_EN




5268854 unindependant crossarm no.' 1 NCD7907_EN




5268874 Device of cable drop and parts for

cable fixing – zone "A"

NCD7912a_EN


cable fixing – zone "B"

NCD7912b_EN


cable fixing – zone "C"

NCD7912c_EN


cable fixing – zone of extension 6m

NCD7912d_EN



NCD7251e_EN



NCD7912f_EN

TMC2G adjusted for

air terminal

with

termination in

20º inclined


5220910 Standard tower NCD7297_EN including

JDHK9089_EN, NCD7545_EN,

NCD9155_EN ,NCD9156_EN,



3663036 Upper and lower unindependant

crossarm 4m

JDHK9087_EN

5220897 Crossarm for air terminal NCD3710_EN

5220898 Drops and fixing cables "TAIHAN" –

zone of tower

NCD6484_EN


zone of extension 6m

NCD7480_EN


zone of extension 3m

NCD7479_EN

5221454 Lightning defenders hanging

arrangement "SIEMENS"

NCD6719_EN

5221527 Tension arrangement on crossarm NCD4184a_EN


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Tower Type IEC Ca. No.' Description Drawing No.'

DSG2G --- Tower structure layout JDHK8800_EN

2797124 Standard tower JDHK8800_EN including

JDHK8801_EN, JDHK8802_EN,

JDHK8803_EN ,JDHK8804_EN,


,JDHK8807_EN

4486221 Standard tower without element no.' 7 JDHK8800_EN including




2797132 Extension No.'1 3m JDHK8808_EN

2797157 Extension No.'1 6m JDHK8809_EN

3662657 Earthwire crossarm unindependent

for assembly 5.5m

JDHK8810_EN

3662665 Upper and lower crossarm

unindependent for assembly 10.7m

JDHK8811_EN, JDHK8811a_EN

3662673 Middle crossarm unindependent for

assembly 11.5m




NCD1057_EN, NCD1057a_EN


assembly 8.5m


DTG2G --- Tower structure layout JDHK8820_EN

2797215 Standard tower JDHK8820_EN including



JDHK8825_EN JDHK8826_EN

,JDHK8828_EN

3340254 Standard tower without element no.' 7 JDHK8820_EN including



JDHK8825_EN JDHK8826_EN

2797256 Extension No.'1 6m (-3) JDHK8829_EN

2797272 Extension No.'2 6m (+3) JDHK8830_EN

3692837 Crossarm for earthwire 5m JDHK8831_EN, JDHK8831a_EN

3692977 Crossarm for earthwire 8.5m JDHK8834_EN, JDHK8834a_EN





unindependent for assembly 11m

JDHK8835_EN, JDHK8835a_EN,


assembly 7.5m

JDHK8833_EN, JDHK8833a_EN,


assembly 12m






assembly 8.8m



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Annexure 15


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ANNEXURE "E" - ITP for Overhead lines steel lattice towers

No. Inspection activities/ Part

examined Document

Inspection by Applicable

Standards Remarks

Sup IEC

Raw material, Workshop procedures, WPS and PQR.

1 Raw material chemical comp.,

mechanical prop.

Material certificate, MTR

IEC National Grid Spec.

H H

Documented

as per EN

10204 3.1, part

of final

documentation

.

Shall be verified by

IEC Metallurgic

Laboratory.

All hot galvanized

steel shall contain

less than 0.04% or

0.12% - 0.25%

silicon

2 WPS and PQR (if applicable)

NDT procedures

Work procedure,

Workforce certificate

H H

As per Spec.

Welders will

be certified for

weld fillet and

tangent

welding

Has to be approved

by IEC Metallurgic

Laboratory.

In-Process Inspection

3 Approved manufacturing

drawing. Machine tools

alignment.

IEC Spec., Supplier work

procedures. R SW

At least 10% of

parts.

4 Visual Inspection of parts,

Geometric measurements.

IEC spec., Approved

drawings R SW At least 10% of

parts.

5 Visual inspection of welds.

NDT (if needed)

IEC spec., Approved

drawings

H SW

AWS D1.1 At least 10% of

parts.

NDT results has to

be approved by IEC

Metallurgy

Laboratory.

6 Full Assembling of one of each

type of tower

IEC spec., Approved

drawings H H

IEC Spec.,

Approved

drawings

Galvanization 7 Visual inspection.

Thickness measurement.

IEC spec., Approved

drawings

H SW

IEC Spec.,

Suppl. Records

At least 10% of

parts.

Repair if needed,

must be approved

by IEC before

conducting.

8 Packing, Final documentation. IEC spec., Parts Packing

Lists H H

IEC Spec.,

Suppl. Records

At least 10% of

packing shall be

verified.

R - Quality Record W - Witness Point

H - Hold Point

SW - Sample Witness

Point


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Revisions:

1.

Appendix "B" – updated.

Added Annexure 13 – bolts dimensions

.Para. 8 - Marking changed , Annexure 6a changed

Added Annexure 14 – IEC Ca. No.'

Added Annexure 15 – Example for crossarm, packing view.

2. Annexure 14 - updated.