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274 MILLION TPY PORTLAND CEMENT PRODUCTION PLANTCONTRACT DOCUMENTDoc 1Production Performance GuaranteesRevision 2003 A) Production Performance Guarantees for “Tests on Completion”A1) Individual Tests of Area, System or Sub-systemLimestone Quarry Operation – for information to CP2 -Capacity: 65,000 t per week (dry)Guaranteed 1,700 t/h (dry) Feed Moisture 5 % Max Feed size: 5 m MaxTest Duration:: 3 Test each 6 hoursMaximum interruption: no InterruptionQuaternary Quarry Operation – for information to CP2 -Capacity: 9,000 t per week (dry)Guaranteed 230 t/h (dry) Feed size: 5 m MaxFeed Moisture 13 % Min 27 % Average 40 % Max Test Duration:: 3 Test each 6 hoursMaximum interruption: no InterruptionLimestone/Quaternary CrusherGuaranteed output: > 1,100 t/h (dry)Feed size: 5 m Max Feed Moisture Limestone 5 % Max Quaternary 13 % Min Quaternary 27 % Average Quaternary 40 % Max Mix ratio Limestone 85 % Quaternary 15 % Guaranteed product size: <80mm 95 % <150mm 100 % Lifetime for hammers: 1250 Operation hours Test Duration: 3 Test each 6 hoursMaximum interruption: 5 Minutes for each testLimestone/Quaternary Long Belt ConveyorCapacity guaranteed > 1,250 t/h (dry)Limestone/Quaternary Mix Pre-Blending StorageFeed material: Product of the limestone/quaternary mix crusher Storage Capacity: > 50,000 t (dry) Stacker capacity guaranteed: > 1,200 t/h (dry) Reclaimer capacity guaranteed: > 520 t/h (dry) Blending effect: Standard deviation CaCO3 <5% Stacker: Test Duration: 3 Test each 6 hoursMaximum interruption: 5 Minutes for each testReclaimer: Test Duration: 3 Test each 6 hoursMaximum interruption: 5 Minutes for each test Raw Mill:Feed size: <80mm 95 % <150mm 100 % Feed Moisture H2O by weight 8 % Max Feed Composition Limestone/Quaternary 98 % MaxHigh Grade Limestone 15 % MaxIron Ore 6 % MaxSand 11 % Max Guaranteed output: ≥520 t/h (dry) Output fineness: ≤12% residue 80 micron ≤ 1% residue 200 micron Output moisture: H2O by weight ≤ 1 % Lifetime guarantee: Roller table and roller liners ≥15,000 Operating hoursand ≥ 7,275,000 Tons of raw meal Test Duration: 2 Test each 24 hours Maximum interruption: One time 15 Minutes for each testRaw Meal Homogenizing Silo:Capacity: 19,000 Ton Standard deviation in CaO of discharge raw meal guaranteed 2 % Max Homogenizing ratio at 50% filling degree guaranteed 5:1 Min Degree of emptying guaranteed 98 % Min Test Duration: 1st Test 36 Hours2nd Test 72 Hours Maximum interruption: 1st Test 2 Times 15 minutes2nd Test 2 Times 30 minutes Number of Samples: Not less than 1 sample per hourPreheater Kiln:Guarantees: Clinker quality for PII 5 cement has to be according to Chinese Regulations but of not less quality than specified in: Doc [Product Requirements ]Capacity ≥ 1,920,000 t of clinker in 320 daysresulting in ≥6,000 t clinker per day Free lime in clinker minimum 85% of production ≤ 0 % CaO maximum 15% of production ≤ 5% CaOCompression strength of clinker at 3,500+100cm^2/gr 3 days28 days >36 MPa >5 MPa Free lime (CaO) standard deviation 12 Specific heat consumption: ≤ 737 kcal/kg clinkerDust content after Preheater ≤ 50 g/Nm3 Fuel Distribution: Kiln fuel for guarantee test 40 %Calciner fuel for guarantee test 60 %Calciner: Design Guarantee fuel 100 % Anthracite Trial run for entitlement to Production Performance Tests: 7 continuous days ≥ 85 % of 6,000 t/d clinker resulting in > 35,700 t Maximum interruption in total: 105 minutes, raw meal feeding to kilnTest Duration: for producing minimum 18,000 ton of qualified clinker per test 3 tests (1 “on Completion” 2 “after Completion”) each test 72 Hours Maximum interruption: 15 Minutes per 24 hoursor 30 Minutes within 72 hoursClinker Cooler:Guarantees: Capacity of cooler for all size of Clinker fitting to kiln requirements > 6,000 t of clinker per day Clinker outlet temperature for all type of clinker (Above ambient temperature in the shade measured at the Cooler Building) ≤ 60 °C Cooler efficiency: ≥ 2 % At specific grate load: ≤ 45 t/d per m2At ambient temperature of: ≤30 °C Trial run for entitlement to Production Performance Tests: 7 continuous days ≥ 85 % of 6,000 t/d clinker resulting in > 35,700 t Maximum interruption in total: 105 minutes, stop of cooler driveTest Duration: for producing minimum 18,000 ton of qualified clinker per test 3 tests (1 “on Completion” 2 “after Completion”) each test 72 HoursMaximum interruption: 15 Minutes per 24 hoursor 30 Minutes within 72 hoursClinker Storage:Capacity 126,000 t clinker Guaranteed degree of emptying by gravity 87 % MinimumLifetime of Refractory Materials on Area 40:Kiln Inlet Zone 16,000 Operating hoursTransition zone Sintering zone 16,0008,000 Operating hoursOperating hoursPre-Heater and Calciner and Terliary Air Duct: 16,000 Operating hours Clinker cooler: High Temperature zone 10,000 Operating hoursLow Temperature zone 16,000 Operating hoursKiln hood: 10,000 Operating hoursCement Grinding:Guaranteed product temperature before silo ≤ 70 °CGuarantee performance PII 5 / PII 5 at 3,600 BlaineOn closed circuit mill (2 systems) 95 t/h eachOn open circuit mill (3 systems) 83 t/h eachIndicative performance data for Area 50: for each mill closed circuit kWh/t t/hPO 5 00 103PO 5 00 103PC 5 00 115for each mill open circuit kWh/t t/hPO 5 00 90PO 5 00 90PC 5 50 100 Guaranteed working hours of life time for lining and internal parts of mills: First Compartment Liners 15,000 Operating hoursSecond Compartment Liners 20,000 Operating hoursSlotted Plates for Partition 15,000 Operating hoursBlind Plates for Partition 15,000 Operating hoursSlotted Plates for outlet diaphragm 20,000 Operating hoursGrinding Media consumption 40 gram/tTest Duration for each mill: 2 times 24 hours Maximum interruption: 1 time 15 minutes each testCement Storage:Total capacity 90,000 t netSingle cell silo 2 x 1 cell each 15,000 t netDouble cell silo 4 x 1 cell each 10,000 t net 4 x 1 cell each 5,000 t net Guaranteed degree of emptying each silo 98 % MinimumRotary Packing Machines:Guaranteed total output for 50 kg bags: 2 x 100 t/h (loaded on rear open truck) Accuracy of Bag weight: According to Chinese For 20 single random bags of 50 kg, deviation in weight of each bag shall be not more or less than 500 Test Duration: 2 times 8 hours Maximum interruption: 15 minutes each test each Rotary Packing MachineBig Bag Loading Station:Guaranteed total output for 1,000 kg bags 1 x 40 t/hBulk Cement Truck Loading Station:Number of cement types to be loaded 5 Number of bulk loading systems 4 Guaranteed total output for each type of cement, measured from “Start Loading” to “End of Loading” 250 t/h for each Loading SystemBulk Cement Ship Loading:Guaranteed total loading time for barge of 300 dwt size from berthing to departure 75 minutesRaw Coal Ship Unloading:Unloading capacity guaranteed for 300 dwt ship size from berthing to departure 180 minutes Coal grain size <50 mm 95 %<80 mm 100 %Coal moisture content 12 % Maximum Test Duration: 2 tests each 3 ship Maximum interruption: none Coal Dust Silo:Guaranteed Total capacity 400 t coal dust Guaranteed degree of emptying 100 %Coal Mill:Feed size: <50mm 95 % <80mm 100 % Feed Moisture 12 % Max Feed Type Anthracite 100 % Guaranteed output: 45 t/h (dry) At output fineness: <5% residue 80 micron <5% residue 200 micron Output moisture: <1 % Lifetime guaranteed: Table liner and roller liners 15,000 Operating hoursbut not less than 675,000 Tons of Coal Dust Test Duration: 2 Test each 24 hours Maximum interruption: One time 15 Minutes for each testCoal Pre-Blending Storage:Coal grain size <50 mm 95 % min<80 mm 100 % max Coal moisture content, H2O by weight 12 % Maximum Storage capacity guaranteed: 2 x 17,500 t (dry) Stacker capacity guaranteed: 225 t/h (dry)Reclaimer capacity guaranteed: 60 t/h (dry) Homogenizing ratio at 100% filling guaranteed 11:1 Standard deviation of Carbon, but not less than 1% standard deviation at Test Duration: 2 Test each 8 hours Maximum interruption: none Shared Raw Material Storage:Guaranteed Storage Capacities : High Grade Limestone 6,750 t (dry)River Sand 2,750 t (dry)Quarry Sand 2,000 t (dry)Iron Ore 10,000 t (dry)Reserve (equivalent to limestone) 2,000 t (dry) Guaranteed stacking capacity: High Grade Limestone and Quarry Sand Stacker 1,200 t/h (dry)River Sand Truck / Dozer 100 t/h (dry)Iron Ore Truck / Dozer 100 t/h (dry) Reclaiming guaranteed for each: High Grade Limestone 2 x 90 t/h (wet) by LoaderBoth Sand types 1 x 90 t/h (wet) by LoaderIron Ore 1 x 90 t/h (wet) by Loader Precondition: Moisture content High Grade Limestone 2,5 % MaximumSand 5 % MaximumIron Ore 22 % Maximum Test Duration: 2 Test each 8 hours Maximum interruption: none Gypsum Storage - Uncrushed:Total out-door storage capacity 10,000 t Feed size: 500 mm Maximum Feed Moisture 5 % MaximumStacking capacity guaranteed by loader 200 t/h (wet)Reclaiming capacity guaranteed by loader >100 t/h (dry)Gypsum/Iron Ore/Coal CrusherFunctionality must be given for:Feed size: Gypsum 100% < 500 mm 90% < 300 mmFeed size: Iron Ore 100% < 500 mm 90% < 300 mmFeed size: Coal 100% < 300 mm 90% < 100 mm Feed Moisture Gypsum 5 % Max Iron Ore 22 % Max Coal 12 % Max Output for gypsum guaranteed: 100 t/h (dry) Guaranteed product size: < 50 mm < 95 % < 80 mm 100 % Lifetime for wear element based on gypsum: 2 years Test Duration: 3 Test each 6 hoursMaximum interruption: 5 Minutes for each testSand Ship Unloading:Unloading capacity guaranteed for 300 t standard ship size1 x >100 t/h (dry) Emptying cargo hull 180 Minutes Sand grain size <10 mm 95 %<20 mm 100 %Precondition: moisture content 6 % Maximum Test Duration: 2 tests each 3 ship Maximum interruption: none General Emission Limits:NOx guaranteed < 500 mg/Nm3SO2 guaranteed << 400 mg/Nm3Noise at Plant Boundary:Daytime guaranteed ≤60 dB (A)Nighttime guaranteed ≤50 dB (A)Dedusting Filters:Process filters for Kiln and raw mill Cooler if applicable Cement mills Coal mill Process filter type Bag Standard filter type Bag Guarantees for process filters dust emissions < 10 mg/Nm3 Lifetime of bags for 4020-4 see extended warrantees Compressed air consumption for 4020-4 1,388 Nm3/h Lifetime of bags for cement mills and coal mill filters 15,000 operation hours Guarantees for standard filters dust emissions < 10 mg/Nm3lifetime of bags 15,000 operation hoursGuarantee of Specific Power Consumption at Guaranteed Capacity:Group including illumination and other production related consumers:20 Raw Material Preparation 06 kWh/t raw mix30 Raw Meal Preparation 14 kWh/t raw meal40 Clinker Production 01 kWh/t clinker50 C Manufacturing PII 5/5 closed 0 kWh/t cement50 C Manufacturing PII 5/5 open 7 kWh/t cement60 Cement Packing and Dispatch 82 kWh/t cement0640 Coal Fuel Preparation 90 kWh/t coalTotal specific power consumption based on the production of the Cement type PII 5 or PII 5 at 3600 cm^2/ “Blaine” produced on open circuit mills only, packed and loaded on trucks 5 kWh/t of cement, “non production related departments” indicative 2,100, kWh per yearThe Guaranteed Specific Power Consumption per group may be adjusted after the completion of the design if approved by the E However the guaranteed Total Specific Power Consumption (5 kwh/ton cement) must remain as Test Procedures for the Individual Areas and/or Sub-Systems:The Tests shall be fulfilled within the operation hours specified in Doc 4 [Group Limits and Requirements] wherever Guaranteed Capacities: The capacities of the various equipment will be determined by weighing the resultant product either continuously by means of the weighing equipment of the department or by means of the weighing bridges of the plant using trucks after calibration of the weighing Measuring tolerance will not be more than +5% Power Consumption: The power consumption of the respective department will be measured on the medium voltage Measuring tolerance will not be more than +1% Fuel Consumption: The fuel consumption of the respective department will be measured by the calibrated counters of the fuel dosing Measuring tolerance will not be more than +5 % Heat Value of Fuel: The heat value of the fuel will be determined by a local neutral authority three times during the test period of the respective PA2) Interlocked TestA1) Production Performance Guarantee Area 20, 30, 40, 06 and related auxiliary departments:Precondition: Operation times shall be as given in Doc 4 [Group Limits and Requirements]1 test 72 hoursMaximum interruption of clinker production: 3 times 15 minutes per 24 hours or 1 times 30 minutes within 72 hoursThis test may be combined in sequence with the tests “A1) Individual Production performance Test” for the Pre-Heater Kiln and interlocked test for “A2) A2) Production Performance Guarantee Interlocked Areas 50, 60 and related auxiliary departments:Precondition: Operation times shall be as given in Doc 4 [Group Limits and Requirements]1 test 72 hoursMaximum interruption of cement production/dispatch: 3 times 15 minutes per 24 hours or 1 times 30 minutes within 72 hours This test may be combined in sequence with the tests “A1) Individual Production Performance Test” for the Pre-Heater Kiln and interlocked test for “A1)A3) Production Performance Guarantee Area 40 Clinker Production (reliability/availability):This test can be carried out either before or after Taking-The guaranteed performance shall be not less than 90,000 tons of qualified clinker in 15 continuous daysMaximum Interruption: 16 hours accumulated for kiln feed but including only one (1) kiln main drive stopThis test may be combined in sequence with the “A1) Individual Test” for the Pre-Heater Kiln and interlocked test for “A1)B) Production Performance Guarantees for “Tests after Completion” B1) 1st Test after Completion:The “Tests after Completion” shall comprise the all described for A) Production Performance Guarantees “Tests on Completion” except “A3) Production Performance Guarantee for Area 40 Clinker Production Note! It is a condition of Contract that this Test for “Test after Completion” which is intrinsically liked to has to take place at least 3000hrs after the successful completion of the test “A3) B2) 2nd Test after Completion:The “Tests after Completion” shall comprise the all described for A) Production Performance Guarantees “Tests on Completion” except “A3) Production Performance Guarantee for Area 40 Clinker Production C) Entire Works Defects Notification (Warrantee) Period: For explanation see Doc 1 Clause Entire System warrantee for the Plant will be 15,000 Operation hours but not more than 730 calendar days for the rest of the W A Limited number of items as stated hereafter under D) Extended Defects Notification Pfor a D) Extended Defects Notification (Warrantee) Period: The Defects Notification Period shall be extended for the items described Precondition for the extended warrantees: the requirements of the manufacturer for operation and maintenance shall be strictly Just before Employer and Contractor and the quality shall jointly inspect end of the “Extended Warrantee Time”, the items of warranty shall be confirmed as “not reduced quality”, otherwise defects or damage shall be Remedy shall be provided and the “Defects Notification Period” shall be expired as stated in Doc 1 [Conditions of Contract]Raw mill main gear box 5 yearsRaw mill main motor bearings* 100,000 Operation hoursRaw mill fan motor bearings* 100,000 Operation hoursCement mill main gear box 4 yearsCement mill main motor bearings* 100,000 Operation hoursCoal mill main gear box 5 yearsCoal mill main motor bearings* 100,000 Operation hoursKiln tires 10 yearsKiln support rollers 10 yearsKiln main drive gear box 4 yearsKiln girth gear and pinion 6 years4020-4 Process Filter fan motor bearings* 100,000 Operation hours4020-4 Process Filter: bags 23,000 Operating hours4020-4 Process Filter bag cages 23,000 Operating hoursClinker Cooler grate plates: for Recuperation Zone 3,840,000 t of clinkerfor Other Zones 3,840,000 t of clinkerfor crusher wear elements 5,760,000 t of clinkerCorrosion of steel structures and/or machinery: 5 years*) The bearings of the motors shall have design lifetime of 100,000 operation