Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) Tender Documents For Ho Chi Minh City Urban Railway Construction Project Ben Thanh - Suoi Tien Section (Line 1) CONTRACT PACKAGE-1B: CIVIL (UNDERGROUND SECTION FROM KM 0+615 TO KM 2+360) VOLUME – OUTLINE DESIGN SPECIFICATIONS TABLE OF CONTENTS Clause Page GENERAL INTRODUCTION 1-1 CODES AND STANDARDS 2-1 2.1 Priority of the Codes and Standards 2-1 2.2 Codes and Standards 2-2 STRUCTURES AND FACILITIES TO BE DESIGNED AND CONSTRUCTED 3-1 3.1 Civil Engineering Structures 3-1 3.2 Building Structures 3-1 3.3 Architectural Finishes for Underground Stations 3-2 3.4 Electrical & Mechanical Services for Underground Stations and Tunnels 3-3 DESIGN CRITERIA DESIGN LIFE 4-1 RAILWAY DESIGN REQUIREMENTS 5-1 5.1 General 5-1 5.2 Stray Current Corrosion 5-2 5.3 Rolling Stock and Construction Gauges 5-2 5.4 Clearance 5-2 RAILWAY ALIGNMENTS 6-1 6.1 Criteria 6-1 6.2 Horizontal Alignment 6-1 6.3 Cant and Speed 6-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 6.4 Transition Curves 6-1 6.5 Vertical Alignment 6-2 6.6 Gradients 6-3 6.7 Levels 6-3 6.8 Points and Crossing Work 6-3 6.9 Distance between Track Centers 6-4 Not Used 7~11-1 Not Used 7~11-1 Not Used 7~11-1 10 Not Used 7~11-1 11 Not Used 7~11-1 DESIGN LOADINGS 12 RAILWAY LIVE LOADS 12-1 12.1 General 12-1 12.2 Nominal Loads 12-1 13 Not Used 13~14-1 14 Not Used 13~14-1 15 SEISMIC LOADING 15-1 15.1 General 15-1 15.2 Method of Seismic Analysis 15-1 16 17 OTHER LOADINGS 16-1 16.1 Not Used 16-1 16.2 Not Used 16-1 16.3 Differential Settlement 16-1 LIVE LOADS IN STATIONS 17-1 GENERAL REQUIREMENT FOR CIVIL AND ARCHITECTURAL DESIGN 18 RAILWAY REQUIREMENTS 18-1 19 GEOTECHNICAL WORKS 19-1 20 UTILITIES 20-1 21 ACCESS FOR INSPECTION AND MAINTENANCE 21-1 22 ENVIRONMENTAL REQUIREMENTS 22-1 22.1 General 22-1 22.2 Air 22-1 22.3 Noise and Vibration 22-1 22.4 Water 22-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 22.5 Land Subsidence and Ground Movement 22-2 22.6 Waste 22-2 23 AESTHETIC REQUIREMENTS 23-1 24 Not Used 24-1 25 SECURITY REQUIREMENTS 25-1 26 DURABILITY AND MAINTENANCE 26-1 27 REINSTATEMENT OF ROADS 27-1 GROUND MOVEMENTS AND BUILDING PROTECTION 28 GROUND MOVEMEMENTS AND BUILDING PROTECTION 28-1 28.1 Ground Movement Analysis Report 28-1 28.2 Utilities Subsidence Report 28-2 28.3 Preventive and Corrective Measures 28-2 28.4 Monitoring 28-2 29 Not Used 29~34-1 30 Not Used 29~34-1 31 Not Used 29~34-1 32 Not Used 29~34-1 33 Not Used 29~34-1 34 Not Used 29~34-1 UNDERGROUND CONSTRUCTION 35 36 37 TUNNEL DESIGN 35-1 35.1 Cut and Cover Tunnels 35-1 35.2 Bored Tunnel Design 35-6 35.3 Underpinning of Existing Structures 35-13 35.4 Ventilation Shafts 35-13 35.5 Sumps in Running Tunnels 35-14 35.6 Tunnel Walkway 35-14 OPEN CUT TRANSITION STRUCTURES DESIGN 36-1 36.1 General Principles 36-1 36.2 Types of Construction 36-1 36.3 Flotation 36-2 36.4 Base Instability 36-2 36.5 Heave and Settlement 36-3 UNDERGROUND STATION STRUCTURAL DESIGN 37-1 37.1 37-1 General Principles of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 38 39 37.2 Types of Construction 37-1 37.3 Flotation 37-1 37.4 Base Instability 37-1 37.5 Waterproofing 37-2 37.6 Heave and Settlement 37-2 UNDERGROUND STATION ARCHITECTURAL DESIGN 38-1 38.1 Introduction 38-1 38.2 Design Requirements 38-2 38.3 Definitions 38-3 38.4 Station Design Criteria 38-6 38.5 Finishes 38-21 UNDERGROUND STATIONS BUILDING SERVICES 39-1 39.1 Description of works 39-1 39.2 General Requirements for E&M equipments 39-15 39.3 Mechanical Works 39-28 39.4 Electrical Works 39-69 39.5 Testing and Commissioning 39-124 Appendix-1A: Mechanical Provision for Underground Stations 39-AP1A-1 Appendix-1B: Electrical Provision for Underground Stations 39-AP1B-1 Appendix-1C: Elevator and Escalator Provision for Undergroud Stations 39-AP1C-1 Appendix-2: Typical Building Automation System Control and Monitoring Point Schedule 39-AP2-1 Appendix-3: Building Services System Design and Construction Interface 39-AP3-1 Appendix-4A: Tunnel Ventilation Fan 39-AP4A-1 Appendix-4B: Not used 39-AP4B-1 Appendix-4C: Tunnel Ventilation Damper Units 39-AP4C-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) OUTLINE DESIGN SPECIFICATIONS GENERAL INTRODUCTION 1.1 This Outline Design Specifications and the Appendices hereto together with the particular Design Specification (as submitted pursuant to Clause of Annex to the Instructions to Tenderers and all as may be modified in accordance with the provisions of that Annex) provide minimum standards which are to govern the design of the Permanent Works These documents shall be amalgamated to form the Contract Design Specification which will be part of the Contractor’s Technical Proposals extant at the date of acceptance of Tender 1.2 The Outline Design Specifications shall be read in conjunction with the Outline Construction Specifications where appropriate 1.3 General Information (1) Topography and Railway Alignment The topography along the railway alignment and railway alignment are shown on the Layout Drawings attached to the Vol Employer’s Drawings (2) Right of Way Right of way for the Project is shown on the Layout Drawings attached in the Vol.6 Employer’s Drawings (3) Geotechnical Information The geotechnical information along the railway alignment is shown on the Geotechnical Profile attached to the Vol.6 Employer’s Drawings (4) Existing Utilities The known existing utilities along the railway alignment and the list of Utility Authorities are shown, for information only, on the Utility Drawings attached to the Employer’s Drawings (5) Existing Traffic Layout The existing traffic layouts along the railway alignment are shown, for information only, on the Traffic Management Drawings attached to the Employer’s Drawings Section 1-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) CODES AND STANDARDS 2.1 Priority of the Codes and Standards The design and construction of the Permanent Works shall comply with following codes and standards, and the priority of these codes and standards shall be in accordance with the following sequence (1) Codes and standards specified in these Employer’s Requirements, Outline Design Specifications, Outline Construction Specifications and other Contract Documents (2) Codes and standards specified in; i) Japanese Ministerial Ordinance providing the technical standards on railways with commentary enacted by the Japanese Ministry of Land, Infrastructure, Transportation and Tourism (Ministerial Ordinance, MLITT-J), ii) Design Standards for Railways Structures and Commentary (hereinafter DSRSC), Railway Technical Research Institute, Japan (RTRI-J), iii) General Specification for Standard Urban Railway System for Asia (STRASYA), Japan Railway Technical Service (JARTS), iv) Standard of Fire Safety Management for Subway Station, etc, MLITT-J, v) Guideline for the Mechanical Facilities of Subway, Japan Railway Construction, Transport and Technology Agency, vi) Plan and Design Guideline for Logistics and Transportation Facility, The Society of Heating Air Conditioning and Sanitary Engineering of Japan, and vii) relevant Vietnamese codes and standards, i.e., TCVN, TCXD and TCN (3) Internationally recognized and equivalent to mentioned above codes and standards which have been approved by HPC (4) The other alternative or additional codes and standards proposed by the Contractor In this case the Contractor shall be responsible for getting approval from MOT prior to the submission of Inception Report The codes and standards shall be current at the time of submission of Tender except where such codes and standards are modified in the Outline Specifications and where the Contractor considers the approved or specified standards to be inappropriate for the Permanent Works Regulations made and requirements issued by the Vietnamese Government and by relevant authorities shall be followed and specified The codes and standards listed in Appendix 28 to the Employer’s Requirements in Volume were already approved or under approval procedure for the Project The Contractor does not need to get approval from Vietnamese competent organizations for the application of those standards Section 2-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 2.2 Codes and Standards 2.2.1 Details of DSRSC Design Standards for Railways Structures and Commentary (DSRSC) as mentioned in Chapter 2.1 is subdivided into followings: (1) Design Standards for Railway Structures and Commentary (Earth Structures); DSRSC-ES (2) Design Standards for Railway Structures and Commentary (Concrete Structures); DSRSC-CS (3) Design Standards for Railway Structures and Commentary (Shield Tunnel); DSRSCST (4) Design Standards for Railway Structures and Commentary (Steel-Concrete Hybrid Structures); DSRSC-HS (5) Design Standards for Railway Structures and Commentary (Cut and Cover Tunnel); DSRSC-CT (6) Design Standards for Railway Structures and Commentary (Seismic Design); DSRSC-SD (7) Design Standards for Railway Structures and Commentary (Urban Mountain Tunnel); DSRSC-UT (8) Design Standards for Railway Structures and Commentary (Displacement Limits); DSRSC-DL (9) Maintenance Standards for Railway Structures and Commentary; MSRSC (10) Design Standards for Railway Structures and Commentary (Foundation Structures and Earth Retaining Structures); DSRSC-FS (11) Design Standards for Railway Structures and Commentary (Steel- Concrete Composite structures); DSRSC-SC 2.2.1 Vietnamese Standards Following are the examples of relevant Vietnamese Standards (1) TCXDVN375-2006; Design of Structures for Earthquake Resistance, (2) TCXDVN356-2005; Concrete and Reinforced Concrete Structure – Design Standard) (3) TCXDVN338-2005; Steel Structure – Design Standard (4) TCVN 2737-95; Loads and Impacts Section 2-2 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) STRUCTURES AND FACILITIES TO BE DESIGNED AND CONSTRUCTED The structures and facilities to be designed, constructed, and provided by the Contractor under this Contract are subdivided into followings, Civil Engineering Structures, Building Structures, Architectural Finishes and Electrical and Mechanical Services for Under Ground Stations Outlines are described below It is to be noted that in addition to the Outlines of structures and facilities described below, the Contractor shall design and construct structural measures to ensure a smooth extension to CP-1a by provision all related necessary bearing structures and interface E&M features at the end wall of the Opera House station The breakthrough and connection works from CP-1a section shall not affect or damage the installed facilities in Opera House Station of CP-1b by vibration, dust etc… 3.1 Civil Engineering Structures The civil engineering structures to be designed and constructed by the Contractor are subdivided into followings, Underground Stations, Bored Tunnels, Cut & Cover Tunnels, and Open Cut Transition Structure The location of major civil engineering structures are summarized as below (1) (2) Underground Station - Opera House Station (km 0+615 to km 0+805) - Ba Son Station (km 1+586 to km 1+826) Bored Tunnel - (3) Cut & Cover Tunnel - (4) Opera House Station - Ba Son Station (km 0+805 to km 1+586) Ba Son Station - Open Cut Transition Structure (km 1+826 to km 2+226) Open Cut Transition Structure - Between Cut & Cover Tunnel (km 2+226) - Construction boundary ( km2+360) Details of each structure, requirements and specifications for these structures are described in Clause 35, 36, and 37 in this Outline Design Specifications, and reference drawings are attached as Civil Structure Drawings in the Vol Employer’s Drawings 3.2 Building Structures The building structures to be designed and constructed above ground level by the Contractor are subdivided into followings, Entrance Buildings of Station, Emergency Generation Building, Roof of Open Cut Transition Structure, and Ventilation Towers The locations of major building structures are summarized as below (1) Entrance Buildings of Station - Opera House Station - Ba Son Station Section 3-1 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) (2) Emergency Generation Building - (3) Protection Method for Open Cut Transition Structure - (4) Ba Son Station Between Cut & Cover Tunnel (km 2+226) - Construction boundary (km 2+360) Ventilation Towers - Opera House Station - Ba Son Station Details of each structure, requirements and specifications for these structures are described in Clause 35, 36, and 37 in this Outline Design Specifications, and reference drawings are attached as Building and Architecture Drawings in the Vol Employer’s Drawings 3.3 Architectural Finishes for Underground Stations The architectural finishes for underground station to be designed, constructed, and provided by the Contractor shall include followings, but not be limited to; (1) Station Areas Entrances, canopies screens and flat roofs, passageways, commercial areas, concourse (free concourse/ paid concourse), station platform, voids under platform, etc (2) Circulation and Queuing Stairs, ramps, balustrades, queuing, etc (3) Station Control Rooms Station control room, supervisor’s office, cash and ticket handling room, staff room, staff dormitory facilities, staff toilets lockers and showers, station store, cleaner’s store, refuse storage area, etc (4) Passenger Amenities Commercial area and kiosk, telephones, first aid, benches, bins, artwork, inferior decoration, etc (5) Waterproofing External and Internal Details of requirements and specifications for architectural finishes are described in Clause 38 in this Outline Design Specifications, and reference drawings are attached as Building and Architecture Drawings in the Vol Employer’s Drawings Section 3-2 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) 3.4 Electrical & Mechanical Services for Underground Stations and Tunnels The electrical & mechanical services for underground stations and tunnels to be designed and provided by the Contractor shall include followings, but not be limited to; (1) Environmental Control Systems (ECS) Station air conditioning, mechanical ventilation of underground plant rooms, tunnel ventilation system, smoke control and extraction system, etc (2) (3) Water Supply, Plumbing and Drainage Services • Pumping arrangement for main water supply, seepage and sedimentation sump pumps, fire fighting pumps, jockey pumps, seepage and sewage pump, etc • Automatically control and monitoring of operation of pumps, incoming supply, liquid level controllers, etc • Feeding arrangement of various pumps, • Storage tanks with level monitors, • Sumps for seepage, sewage and suitable drainage system, etc Fire Protection Services Complete fire suppression system in the station, tunnel and buildings including hydrants, hose reels, fire hose cabinets, fire mains in the tunnel, potable extinguishers, clean gas based flooding system and pipe line network with control valves for hydrants and Fire Department (4) Electrical Works • Power and control cables, power panels, interlocks and protection schemes, Uninterruptible Power Supply (UPS) for feeding all emergency loads, complete fire detection and alarm system, etc • Building Automation System (BAS) including all hardwares, cabling and softwares • Normal and emergency lighting arrangement and automatic operation • Lighting, earthing system for the station, lightning protection • Automatic power factor correction system • Elevator and escalators • Other electrical accessory/auxiliary item/equipment/services Details of requirements and specifications for electrical and mechanical services are described in Clause 39 in this Outline Design Specifications, and reference drawings are attached as E & M Drawings in the Vol Employer’s Drawings Section 3-3 of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) (8) After the completion of fan-motor units performance tests, submit for each fan-motor unit size, performance curves and tables of performance data calculated from shop test data, at each of the test points at each rotational direction (9) The tables shall consist of numerical values at each of the test points for the following: (10) (i) Volume of air delivery in cubic meters per second (ii) Fan static pressure in Pascals (iii) Fan total pressure in Pascals (iv) Fan outlet velocity pressure in Pascals (v) Fan total efficiency in percent (iv) Fan static efficiency in percent (v) Kilowatt input to fan impeller (vi) Fan speed in revolutions per minute (vii) Current input in amperes (viii) Voltage in volts (ix) Motor power input in kilowatts and power factor (x) Number of phases and frequency Submit fan-motor unit performance curves verifying the theoretical performance curves previously submitted Test points shall be indicated on performance curves H Noise Test (1) Preproduction unit which has satisfactorily passed all preceding tests and inspections specified shall be tested in accordance with the induct test procedure of JIS standard or equivalent international standard to obtain sound power level data at eight-octave band centre frequencies from 63 Hertz to 8,000 Hertz (2) Fan shall be tested with specified nominal airflow Test data shall be submitted to the Employer’s Representative for consent in tabular form Section 39 AP4A/ 17 of 19 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) PART - EXECUTION A3.01 INSTALLATION METHODS A All fans shall be furnished and installed as specified herein The manufacturer's rigging instructions shall be carefully followed The Contractor shall make certain that the installation of all supports, gaskets, hardware, etc., are accomplished with precision and the exercise of extreme care so as to assure safe, accurate and trouble-free fan installation B The fan installation shall be done in the presence of the Fan Manufacture's Field Service Representative C Prior to proceeding with the work described above, the Contractor shall submit for the Employer’s Representative 's consent eight copies of detailed drawings showing all fan installations including dimensions, supports, hardware, installation methods, and all other pertinent data D Fans shall be connected to transition companion flanges with mm thick solid silicone gasket between E When installed, the orientation of each fan, as to motor end, shall be as indicated on the Contractors Drawings Fans which are improperly installed shall be removed and reinstalled A3.03 FIELD TEST A Upon completion of the installation of the ventilation equipment at the fan room and the installation and verification of the power and local control wiring, the Contractor shall notify the Employer’s Representative in writing at least two weeks prior to the field testing to have the Employer’s Representative present to witness the tests The Contractor shall furnish written instructions for testing of the fan motor units in the field This instruction shall be submitted as a part of the operating and maintenance instruction B Field tests shall be performed under the technical guidance and supervision of the Fan Manufacture's Field Service Representative The Fan Manufacture's Field Service Representative shall provide the field test instrumentation and perform the tests The Fan Manufacture's Field Service Representative shall measure and record the vibration amplitude; power consumption; no-load, starting and full load voltages; starting and full load currents; and acceleration time C Time of operational testing shall be two hours per fan; one hour in each flow direction All fans in a station shall be operating simultaneously when determining and recording the electrical measurement Prior to the operational tests the vibration and electrical measurements shall be recorded for each fan motor unit at design speeds in each direction D Testing for the ventilation equipment shall not be undertaken until electric service and local controls can be provided for testing Section 39 AP4A/ 18 of 19 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) (1) Each fan motor unit shall be checked for obviously rough operation after the fans are installed Defective bearings shall be replaced with new bearings and the fan(s) shall be rechecked Amplitude and frequency of radial and axial vibrations at the bearings shall be measured, recorded, and checked for conformity to the Specifications (2) Each fan motor unit on which the specified vibration field tests have been successfully performed shall be tested to confirm that such fans are operational E (3) When two fans are to start, starting sequence shall be provided with 20 seconds interval Both fans shall achieve full speed in 35 seconds (4) Electricians to energize the ventilation equipment where required and assist the Contractor during testing shall be provided by the Contractor (5) Any defect that develops within the ventilation equipment during the test shall be corrected by the Contractor at no additional cost to the Employer (6) Any defect that develops with the installation work during the test shall be corrected by the Contractor at no additional cost to the Employer After completion of all field tests and after the final visit by the Fan Manufacture's Field Service Representative, the Contractor shall submit a field test and inspection report Field test report shall include copies of raw data, measured results, calculations, and all data derived from tests to confirm compliance with specified performance, noise, vibration and equipment efficiencies END OF APPENDIX 4A Section 39 AP4A/ 19 of 19 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) APPENDIX 4B Not used Section 39 AP4B/ of October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) APPENDIX 4C TUNNEL VENTILATION DAMPER UNITS Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) APPENDIX 4C - TUNNEL VENTILATION DAMPER UNITS C1.0 GENERAL C1.01 DESCRIPTION A This Section specifies the requirements for furnishing motor operated dampers and appurtenances as specified herein Dampers shall be the product of a single manufacturer whose name shall appear on the performance curves and other data submitted and who shall have previously furnished emergency fan and bypass dampers to rail transit agencies C1.02 QUALITY CONTROL A Materials and workmanship shall be in accordance with the latest edition of the relevant Japanese Standards and requirements of MLITT-J C1.03 SUBMITTALS A Before giving the manufacturer Notice to Proceed, the Contractor shall submit to the Employer’s Representatives for review and consent, the names and qualifications of the manufacturer of tunnel ventilation damper units Qualification statement shall include but need not be limited to the following data: (1) Theoretical performance curves for dampers proposed to be furnished under this Contract (2) Actual performance curves verifying the theoretical performance curves previously submitted shall also be furnished as part of the damper unit test results Performance curves shall be plotted to such scales as will make it possible to read the data accurately (i) The damper performance curves shall be damper characteristic curves as follows: (a) Curve plotted with ordinate as pressure drop in Pascals versus face velocity in meters per second (b) (ii) Curve plotted with ordinate as duct pressure in Pascals versus leakage in percentage of maximum flow The following information shall be printed in each performance curve: (a) Project title (b) Name and address of damper manufacturer (c) Name and address of damper operator manufacturer (d) Contractor's name and address (e Damper designation number (f) Air density (g) Damper face area (h) Damper assembly net free area Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) (i) Damper operator model number (j) Electrical or pneumatic characteristics of damper operator (k) Electrical characteristics of damper operator space heater, including voltage and kilowatt input (3) (4) Manufacturer's quality assurance program A complete list of projects on which similar tunnel ventilation dampers for rail transit projects have been installed or furnished List shall include: (5) (i) Name of owner or user (ii) Contract number(s) (iii) Original installation date(s) (iv) Current condition of equipment, including estimate of remaining useful life (v) A list of all known failures including, their apparent causes, corrective work affected, and a description of equipment service and operating conditions List of components proposed to be purchased from other manufacturers, giving name of manufacturer, type and characteristic of each item and applicable data requested under paragraph through above B The Contractor shall submit to the Employer’s Representative a Certificate of Compliance signifying that equipment to be furnished under this Contract meets the requirements specified herein C Within 14 days after successful completion of all factory tests specified herein and of any additional tests conducted at the Contractor's own option, the Contractor shall submit the following: (1) Certified results for all tests conducted All test data shall be bound in one report The test report shall be indexed and cross-referenced in an easily understood manner (2) All records and results of non-destructive examinations made at completion of each examination (3) D Field test procedures Supply the Employer with ten (10) spare damper operators, identical to the operators installed to operate the dampers The damper operator motors shall be complete and labeled with the motor characteristics Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) PART C2.0 PRODUCTS C2.01 MOTOR-OPERATED DAMPERS A Description (1) Dampers shall be furnished complete with damper mounting frames for each damper module and all components and incidentals as specified herein; with all structural support elements and hardware required for installation of the damper modules into composite damper units, and with any additional accessories which may be needed in order to meet the performance requirements as provided in these Specifications (2) All like components shall be furnished by a single supplier (3) Each damper module shall have integral channel frames with interconnecting linkage between modules and operators which shall permit all blades in damper assembly to operate in unison Modules shall be individually removable from composite assembly All damper modules shall be surface mounted against the face of structural steel members, (columns, mullions, lintels, beams and embedded framing members) which shall be furnished by the damper manufacturer, and installed by the installing Contractor Structural steel members shall have pre-drilled companion flanges matching the size and spacing of mounting holes in each damper module frame (4) Dampers and damper companion flanges may be fabricated in multiple sections where required The sections shall be interconnected with bolted splice plates The sections shall be of such size, which can be brought into the fan rooms and vent shafts through the access provided and to facilitate handling, erection and disassembly Prior to fabrication, the existing concrete openings for dampers and the equipment access shall be field verified (5) Linkages and bearings of all damper modules shall be arranged in such a manner, that they are easily accessible upon removal of gasketted cover plates, without removal of entire damper module B Damper Requirements (1) All motor operated dampers furnished shall be suitable for installation in either a vertical plane or a horizontal plane, as required (2) The dampers shall be designed to be readily assembled in the field from modular panels Each damper panel shall be of the multiple parallel blade type, with an independent channel frame; and shall be factory assembled complete with frames, blades, shafts, bearings, seals, linkage, and all accessories required to erect the modular panels into composite damper units which are functional as specified herein Dampers shall be furnished complete with all structural support members and hardware required to complete the installation (3) Multiple modular panel dampers may be operated by use of jack shafting Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) (4) Dampers shall be arranged for electric or pneumatic motor operation to two blade positions: fully-open and fully-closed Each damper shall be furnished complete with electric or pneumatic motor operators sufficient in number and capacity to actuate all modular panels in a damper unit in unison under the operating conditions specified herein Dampers shall be suitable for continuous operation in either open or closed position (5) Motor operated dampers shall have a net free face area of not less than 80 percent measured to the inside of the damper frame clear opening when blades are fully open (6) Upon loss of power, dampers shall move to the power-off position (open or closed) as indicated by the Contractors design (7) Motor operated dampers shall be so designed that the dampers will be fully operational in accordance with the performance requirements specified herein after exposure to an airstream temperature of 250 degrees C for one hour Dampers and components shall be capable of withstanding the stresses caused by pressure transient pressures from train piston action, and by reversal of airflow and thermal shock caused by temperature changes of from to plus 250 degrees C Submit manufacturer's certificate of compliance and the results of previous test if conducted for certification of such requirements (8) Each damper module shall be provided with two blade mounted limit switches for remote indication of the damper position, one for fully open position and one for fully closed position Switches shall be provided with independent contacts mounted to positively detect full-open and full-closed positions Limit switches for dampers required to operate in high temperature shall be suitable for operating at 250 degrees C for one hour (9) For multiple module dampers, and dampers that operate in a group, limit switches shall be wired in series to provide a common open or closed indication for each damper unit, or damper group (10) All power and signal wiring for damper operators and limit switches shall be wired to barrier strips in common weatherproof cast iron terminal box, drilled and tapped for one-inch conduit, and mounted on the damper mullion or other suitable position If necessary, the terminal box can be removed for shipment, but the manufacturer shall provide adequate instruction for installation and electrical connection in the field C Damper Performance Damper and Motor assembly shall be capable of being fully cycled (open to close to open, or vice versa) for a minimum of 100,000 cycles before failure occurs Damper manufacturer shall submit a certificate along with test data guaranteeing this performance Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) C2.02 DAMPER FABRICATION AND COMPONENTS A Damper blades shall have an airfoil cross-section and shall be fabricated of Type 304 stainless steel or aluminum alloy extruded to a minimum thickness of 2.5 mm The width of the blades measured in the direction of airflow shall not be less than 150 mm and shall not be greater than 300 mm Damper blades in the open position shall not extend beyond the damper frame Damper blades shall have metal to metal overlap in the closed position Blade edge sealing strips, regardless of their composition, will not be permitted as a substitute for a true blade to blade overlap B Damper blade shafts and jack shafts shall be fabricated of stainless steel Type 304 Blade shafts shall be full-length construction and shall be not less than 20 mm in diameter or square Jack shafts shall be not less than 25 mm in diameter The design of the damper blade shafts shall incorporate the devices required for locking the blades onto the shafts Damper blade shaft axis shall always be horizontal C Damper blade deflection, with blade supported by shaft, shall not exceed 1/360 of the span length between centers of shaft bearings with damper in closed position while withstanding the maximum combined differential pressure of 2500 Pa and maximum temperature of 250 degrees C D The damper blade and shaft assemblies shall be supported at each end by means of selflubricating sleeve type bearings, suitable for operating at 250 degrees C for one hour Bearing mounting shall be external to frame E Damper linkage shall be external heavy duty industrial type, fabricated of stainless steel Type 304 not less than mm by 20 mm flat bars Linkage shall interconnect damper blade shaft crank arms which shall be fabricated of stainless steel not less than mm thick The linkage bearings shall be fabricated of reinforced thermo plane of other material suitable for the specified operating conditions, as approved by the Employer’s Representative The linkage brackets shall be side mounted and mechanically interconnected with the shafts Arm to be welded to axles Linkage shall be capable of transmitting a minimum of 150 percent of operator load All linkage parts and assemblies shall be accessible for maintenance and repair after final assembly A turnbuckle linkage adjustment shall be provided with each linkage to provide a convenient means of adjusting the length of the connecting rod and thereby the damper closure F Damper frames shall be a channel cross-section with not less than an 200 mm or greater than 300 mm web and not less than 80 mm flanges on the mounting side or less than 50 mm on the opposite side and shall be fabricated of stainless steel Type 304 with a minimum thickness of mm Reinforcing bosses, and dovetail grooves for mounting frame seals, shall be integral parts of the channel configuration The corners of the frames shall be welded and reinforced by means of riveted gusset plates Linkage elements shall be sized so that the maximum deflection of any element shall not exceed L/360, where "L" is the length G Motor operated dampers shall be furnished complete with all structural support elements necessary for the installation of the dampers, including the following: all intermediate supports, both horizontal and vertical; all clip angles and other framing members as required at the head, sill, mullion and jambs of each damper assembly; and all screws, bolts, nuts, washers Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) and other hardware required to complete the installation All intermediate supports, framing members, and hardware required for assembly and installation of the damper modules shall be fabricated of stainless or cadmium plated steel H Lifting lugs shall be of the same material as the exterior damper frame not less than mm thick steel and shall be welded on exterior of damper frame in sufficient number to facilitate future on-site installation and removal Lugs shall be a minimum of four per each knocked down damper component or frame and spaced to prevent deformation of component when suspended from chains during installation I Damper companion flange grid assemblies shall match the damper frame J Mullion supports shall be designed by the Contractor The mullions shall be the full length and width of the dampers Mullion supports shall be of galvanized steel and shall have punched or drilled holes, equally spaced for damper module attachments Number of holes and space between the holes shall be selected by the Contractor Mullion supports shall be installed by the Contractor The Contractor may recommend alternative method for mullion attachment to damper companion flanges and align the equipment with the flange (1) Flanges shall have punched or drilled holes equally spaced not more than 150 mm on centers (2) In accessible areas, fasteners shall be hexagonal head bolts with hexagonal nuts, provided with heavy-duty lock washers (3) In inaccessible areas, fasteners shall be hexagonal head tap bolts, provided with heavy-duty lock washers (4) Bolts shall be not less than 12 mm in diameter Nuts and bolts shall conform to the requirements of relevant Japanese Standard or equivalent international standard, with suitable lock washers K Damper operator mounting brackets shall be fabricated of not less than mm thick stainless steel Type 304 and shall be bolted to the mounting surface Mounting bracket shall be constructed in such a manner that bracket cannot be moved by hand to cause binding or misalignment of bearing(s) and damper shaft(s) L The Contractor shall provide a mm thick silicone base gasket covering the full width of each flange between damper frames and damper companion frames and between damper frames and other associated companion flanges Gasket material shall be suitable for 250 degree C for one hour without emitting toxic or noxious fumes M Mounting members for Wall Mounted Dampers All mounting members needed to install each wall mounted damper in its respective opening shall be furnished and installed by the Contractor All mounting members shall be galvanized steel angles all sides, size 80 mm by 80 mm by mm The mounting members shall be fastened to the damper by means of stainless steel fasteners Each damper shall be brought to the site as an integral unit, except that mounting members shall be fastened and installed in the field The mounting members specified in this paragraph are in addition to the module and damper frames specified herein N Provide the Employer with technical support bearings Quantity of technical support bearings Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) shall be five percent of each type used on dampers Bearings should be stored in secure storage containers with permanent labels identifying number, type, manufacturer, bearing location on dampers, and the Employer Contract Number C2.03 DAMPER OPERATOR REQUIREMENTS A The damper operators may be electrical type or pneumatic type Electro-Hydraulic operators shall not be used The motor operators shall be capable of actuating the dampers as specified herein against differential pressure of 2500 Pa across the dampers The operators shall be capable of changing the position of the dampers from fully closed to fully open, or from fully open to fully closed within a period of not more than 30 seconds Time duration to close or to open the damper shall be adjustable in the field The operators shall be selected and their required quantity shall be determined, such that the normal torque output required for each damper or damper section does not exceed two-thirds of the rated operator capacity This selection criterion provides that each operator has at least 50 percent excess capacity However, in no case shall there be less than two motor operators provided per damper installation, and each operator shall be linked independently to damper sections of equal size Motor operators shall be able to operate continuously under the specified ambient temperature conditions B Linkage from the damper operator shall be fabricated of stainless steel Type 304 and shall be connected to the interconnecting blade linkage with a stainless steel pin, such that full force of operator is applied to the blade connecting linkage C The motors shall be totally enclosed Motor windings and motor leads shall be copper and shall be so insulated that the temperature rise of the insulated motor windings shall not exceed 250 degrees C measured by resistance method, above an ambient temperature of 40 degrees C D Motors shall be equipped with factory installed resistance space heaters within the motor enclosure to prevent condensation of moisture in the motor windings The heaters shall be provided with leads terminated in the conduit box E Pneumatically powered damper actuators shall be of the piston or rotary type with a 550 to 800 kPa working pressure F The actuators shall be furnished with spring actuated devices capable of driving the dampers to their "POWER OFF" positions within a period of 15 seconds after the operators are deenergized The "POWER OFF" position of a damper (normally open or normally closed) is defined as the position which the damper assumes when its operators are de-energized The spring return devices shall be fully operational as specified throughout and following exposure to ambient and air stream temperatures of 250 degree C for one hour G Motor leads and limit switch contacts shall be factory wired to cast iron weatherproof conduit boxes Conduit boxes shall have tightly fitting, gasketted covers designed to resist the entrance of dust and fluids; and shall have threaded conduit openings All electrical components, conduit and boxes shall be weatherproof Conduit boxes shall be mounted to the motor mounting plates H The initial charge of lubricants for damper components shall be supplied by the manufacturer Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) I The Contractor shall co-ordinate with damper manufacturer on the installation of damper motor operators from operational and service standpoint C2.04 DAMPER FINISHING All galvanized parts shall have either a hot dipped or an electro-deposited zinc coating The weight of the coating shall be not less than 750 grams per square meter of surface The zinc coating shall be performed after the material is fabricated The use of zinc pigmented paint in lieu of galvanizing will not be allowed The galvanizing shall conform to relevant Japanese standard; and withstand an eight dip Preece Test in accordance with Japanese standard C2.05 NAMEPLATES A Each damper shall be provided with a stainless steel nameplate permanently stamped with the name and address of the manufacturer, Contractor's model type, serial number and the Employer's designated damper number B Each damper motor shall be provided with stainless steel nameplate permanently stamped with the project title, name of Contractor, name and address of the manufacturer, the motor kilowatt, voltage, phase, frequency, insulation type, full-load current, locked rotor indicating code letters, the design temperature rise over ambient of the motor, the terminal connection chart for the motor, rating of the space heater, speed in revolutions per minute, motor type, service factor, motor serial numbers, bearing numbers and shop order number and the Employer's designated damper number C Nameplates shall be attached to respective component in a location conspicuous after installation C2.06 SCREENS A Screens mounted on damper module frame shall be one-inch galvanized steel wire Each screen shall be complete with a frame for rigidity The screen shall be reinforced across the shorter dimension with 30 mm by 30mm by 3mm galvanized steel angles on 600 mm maximum centers B Screen companion flanges shall be bolted to damper companion flanges with bolts spaced not more than 300 mm on centre C2.07 FACTORY DAMPER TESTS A The Authority may, at his option, witness any or all of the tests specified herein The Contractor shall notify the Employer’s Representative, in writing, in not less than three weeks in advance as to the location and dates of the factory tests B One damper unit shall be subjected to tests The test shall be conducted in a test facility located either at the manufacturer's plant, or at a suitably equipped testing laboratory The test facility shall be consented by the Employer’s Representative C The damper shall be tested in accordance with relevant Japanese standard, the latest edition using a test set-up approved by the Employer’s Representative as appropriate for the intended installation of the dampers Test data shall be recorded on test record forms as consented by the Employer’s Representative Certified test data, and certified performance curves for all of the co-ordinates specified in these Specifications shall be submitted to the Section 39 AP4C/ of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) Employer’s Representative for consent Minimum test section shall be 1200 mm by 1200 mm D Conduct the following performance tests: (1) Maximum leakage in percentage of flow with 2500 Pa pressure differential across the closed damper (2) Maximum pressure drop across damper in fully open position with a uniform face velocity of 10 m/s (3) A detailed analysis for submission by the manufacturer to demonstrate that the various damper components at their point of critical stress not exceed the endurance limit stress of the material Calculated maximum expected stresses for both the normal design pressure condition and the test condition, together with design properties of the material used to fabricate the damper blades and shafts, shall be submitted to the Employer’s Representative for consent E Operational Test: The damper, while remaining in the fully closed position, shall be subject to not less than 30 pressure reversals in one hour while withstanding a differential pressure of not less than 2500 Pa PART C3.0 EXECUTION C3.01 INSTALLATION METHODS A Dampers – General (1) All dampers, connecting bars, linkages and operators shall be installed and adjusted so that: when a damper is fully open, the damper blades shall be parallel to air flow to provide minimum friction loss and obstruction to airflow, when a damper is fully closed, the damper blades shall be perpendicular to the airflow with seals pressing against mating surfaces along their entire length to provide tight closure and minimum air leakage (2) There shall be no flutter, rattling or vibration of damper, connecting bar and linkage either when the damper is operating or when the damper is in the fully open or fully closed positions Each damper shall be installed so as to provide smooth operation, opening and closing without shock or slamming (3) All damper linkage shall be properly installed and connected to its perspective operator to prevent blade flutter and to insure against connecting bar and linkage distortion or binding during operation Undue flexure or bending of connecting bars and linkage shall be cause for rejection Such connecting bar and/or linkage shall be replaced with either a corrected design, higher strength materials, proper size of components or a combination of the aforesaid, as required (4) Damper and Damper Openings Particular attention is called to the fact that nominal dimensions are often indicated on the drawings for construction of the dampers However, the actual openings where dampers are to be installed may vary from the indicated dimensions In providing dampers to close these openings, the Contractor shall verify all dimensions in the field and shall design and build each frame to fit the Section 39 AP4C/ 10 of 11 October 2012 Ho Chi Minh City Urban Railway Construction Project Outline Design Specifications Ben Thanh – Suoi Tien Section (Line 1) Contract Package-1b: Civil (Underground Section from KM 0+615 to KM 2+360) respective opening, without leaving spaces between the frame and structure All slight unavoidable spaces between the frame and the structure shall be filled to the satisfaction of the Employer’s Representative, so that the damper openings shall be completely airtight The aforesaid spaces shall be filled with grout or neat Portland cement or other approved sealing materials, all properly bonded to the existing surface C3.02 FIELD SERVICE A The Contractor shall provide a field service Representative inspection to ensure that the dampers and damper operators supplied therein are properly installed and tested B Field service shall be performed periodically as required C The Employer’s Representative shall be advised in writing of the name and title of the proposed Damper Manufacture's Field Service Representative, who upon the Employer’s Representatives’ consent shall have complete authority to represent and to act for the Contractor D The duties, responsibilities, and qualifications of the Damper Manufacture's Field Service Representative shall be: (1) Advise installation Contractors on the proper procedures for the installation of the damper equipment (2) To have a thorough knowledge of the damper systems (3) To have a thorough knowledge of the testing of all material and equipment supplied (4) To prepare and submit to the Employer’s Representative a typewritten report on all activities and findings for each visit within 15 working days of each visit The final report shall give results and findings of field tests below E Field Test: (1) The Contractor shall furnish written instructions for testing the dampers in the field as part of the operating and maintenance instructions (2) Each damper shall be subject to rotation reversal tests A cycle of rotation reversal is defined as reversal from fully open to fully closed position, and then back to fully open position Each damper shall require five cycles of rotation reversal (3) After completion of reversal tests each damper operator shall be de-energized and checked to confirm that it is driven to its "power off" position within 15 seconds after being de-energized (4) Damper equipment shall be energized and temporary connections shall be made where required (5) Any defect that develops within the equipment and with the installation work during the test shall be corrected by the Contractor at no additional cost to the Employer END OF APPENDIX 4C Section 39 AP4C/ 11 of 11 October 2012