ankerlig additional storage tanks

Ankerlig Power Station Specification No.

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Employers Works Information

Storage Tank

Specification for Diesel Fuel Oil and Fire Water

Rev 0

December 2011


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File Reference:

Client : Ankerlig Power Station

Project Title: Additional Diesel Storage

Report Title: Additional Storage Tank Specification for Diesel Fuel Oil and Fire water

REV. NO.: 0

Volume: 1 of 1

PRODUCED: Leonard Calana

Tinus Keyser

DATE: 6 December 2011

CHECKED: Phil Khumalo

Mjongi Mdemka

Paul Loots

Pamela Mrubata

Zahir Kapier

Nkahle Sesiu

Lynn Allies

Riaan Mouton

Saleigh Williams


APPROVED: Rodney Booth

TITLE: Plant Manager


Latest Revision Summary:

COPYRIGHT © ESKOM HOLDINGS

ALL RIGHTS RESERVED, NO PART OF THIS WORK MAY BE MODIFIED OR

REPRODUCED OR COPIES IN ANY FORM OR BY ANY MEANS - GRAPHIC,

ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING, RECORDING, TAPING OR

INFORMATION AND RETRIEVAL SYSTEM, OR USED FOR ANY PURPOSE OTHER THAN

ITS DESIGNATED PURPOSE, WITHOUT THE WRITTEN PERMISSION OF ESKOM

HOLDINGS


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TABLE OF CONTENTS

Page No.

1.1. GENERAL REQUIREMENTS ................................................................................. 6

1.1.1 Scope.................................................................................................................................................. 6

1.1.1.1 The Development......................................................................................................................... 6

1.1.1.2 Permits and Licenses .................................................................................................................. 6

1.1.1.3 Scope of the Works...................................................................................................................... 6

1.1.1.4 Exclusions .................................................................................................................................... 6

1.1.2 Site Conditions Access and Contractor’s Area ............................................................................. 7

1.1.2.1 Security ........................................................................................................................................ 7

1.1.2.2 Contractors Compound/Lay-down ............................................................................................... 7

1.1.2.3 Car Parking .................................................................................................................................. 7

1.1.2.4 Roads ........................................................................................................................................... 7

1.1.2.5 Co-operation with Other Site Service Providers/Good Neighbours Policy .................................. 7

1.1.2.6 Site Cleanliness ........................................................................................................................... 8

1.1.2.7 Working Hours ............................................................................................................................. 8

1.1.2.8 Industrial Relations ...................................................................................................................... 8

1.1.2.9 First Aid ........................................................................................................................................ 8

1.1.2.10 Manner of Execution - Personnel ................................................................................................ 8

1.1.2.11 Contractor's Representatives and Personnel .............................................................................. 9

1.1.3 Statutory Requirements, Codes, Building Regulations ................................................................ 9

1.1.4 Project Management ......................................................................................................................... 9

1.1.4.1 General ........................................................................................................................................ 9

1.1.4.2 Contractor’s Representative ...................................................................................................... 10

1.1.4.3 Competence of Welders and other Personnel ........................................................................... 10

1.1.4.4 Welders and Welders Qualification - General ........................................................................... 10

1.1.4.5 Welders’ Test ............................................................................................................................. 11

1.1.4.6 Programming ............................................................................................................................. 11

1.1.4.7 Progress Reports ....................................................................................................................... 11

1.1.4.8 Progress Meetings ..................................................................................................................... 11

1.1.4.9 Project Documentation .............................................................................................................. 12

1.1.4.10 Drawings .................................................................................................................................... 12

1.1.4.11 Calculations ............................................................................................................................... 13

1.1.4.12 Manuals ..................................................................................................................................... 14

1.1.4.13 Plant Identification System ........................................................................................................ 15

1.1.4.14 Procedures ................................................................................................................................. 16

1.1.4.15 Inspection and Tests .................................................................................................................. 17

1.1.5 Site Services .................................................................................................................................... 18

1.1.5.1 General ...................................................................................................................................... 18

1.1.5.2 Water Supply ............................................................................................................................. 19

1.1.5.3 Telephone/Fax ........................................................................................................................... 19

1.1.5.4 Power Supply ............................................................................................................................. 19

1.1.5.5 Sewage System ......................................................................................................................... 19

1.1.5.6 Washing and Sanitary Facilities ................................................................................................. 19

1.1.5.7 Fire Fighting ............................................................................................................................... 19


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1.1.5.8 Personal Protection Equipment ................................................................................................. 19

1.1.6 Quality Assurance ........................................................................................................................... 20

1.1.6.1 General ...................................................................................................................................... 20

1.1.6.2 Quality Assurance, Concept and Control .................................................................................. 20

1.1.6.3 Quality Assurance Manual (QAM) ............................................................................................. 20

1.1.6.4 Works (Manufacturer’s Facilities) Quality Assurance Programme (WQAP) .............................. 21

1.1.6.5 Site Quality Assurance Programme (SQAP) ............................................................................. 21

1.1.6.6 Project Specific Quality Plan (PSQP) ........................................................................................ 22

1.1.6.7 Quality Control Records/Manual ................................................................................................ 23

1.1.6.8 Monitoring by the Employer ....................................................................................................... 23

1.1.6.9 Site ............................................................................................................................................. 24

1.1.7 Safety................................................................................................................................................ 24

1.1.7.1 Contractor’s Obligations ............................................................................................................ 24

1.2. TECHNICAL REQUIREMENTS ............................................................................ 29

1.2.1 Metrological Site Conditions ......................................................................................................... 29

1.2.2 Working Arrangements .................................................................................................................. 29

1.2.2.1 Planning of Work........................................................................................................................ 29

1.2.2.2 Protection of the shell during erection ....................................................................................... 29

1.2.3 Storage Tanks ................................................................................................................................. 29

1.2.3.1 Terminal Points .......................................................................................................................... 29

1.2.3.2 Design Parameters .................................................................................................................... 29

1.2.4 Details of Tanks and Accessories Lots 1 to 2 .............................................................................. 30

4.1.1.1 General ...................................................................................................................................... 30

4.1.1.2 Operational philosophy of Diesel Fuel Oil tanks ........................................................................ 30

1.2.4.1 General ...................................................................................................................................... 31

1.2.4.2 Design Standards ...................................................................................................................... 31

1.2.4.3 Tank Drainage ........................................................................................................................... 31

1.2.4.4 Nozzle Details and Fittings ........................................................................................................ 31

1.2.4.5 Materials .................................................................................................................................... 31

1.2.4.6 Instrumentation .......................................................................................................................... 31

1.2.5 Details of Tank and Accessories Lot 3 ......................................................................................... 34

1.2.6 Corrosion Protection ...................................................................................................................... 36

1.2.6.1 Exterior Paint Protection System ............................................................................................... 36

1.2.6.2 Underside of Tank Floor-plates Paint Protection System ...................................................... 3637

1.2.6.3 Interior Paint Protection System ................................................................................................ 37

1.2.7 Cleanliness, Preparation, Painting, Finishing and Repairs of Painted Surfaces ..................... 37

1.2.7.1 Cleanliness of the System: Treatment of Internal Surfaces ...................................................... 37

1.2.7.2 Protection, Painting, Finishing and Packing .............................................................................. 37

1.2.7.3 Surface Preparation and Conditions for Painting ...................................................................... 37

1.2.7.4 External Tank Painting and Under-floor Plates ......................................................................... 37

1.2.7.5 Internal Tank Painting ............................................................................................................ 3738

1.2.7.6 Priming Coats – Shop Priming Coat ...................................................................................... 3738

1.2.7.7 Post Welding Surface Treatment and Priming .......................................................................... 38

1.2.7.8 Repair of Damaged Paint-work .................................................................................................. 38


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1.2.7.9 Control of Paint Thickness ......................................................................................................... 38

1.2.7.10 Areas for Special Attention .................................................................................................... 3839

1.2.7.11 Compatibility of Paints ............................................................................................................... 39

1.2.8 Pipework .......................................................................................................................................... 39

1.2.9 Tank Labelling ................................................................................................................................. 39

1.2.10 Civil Requirements .......................................................................................................................... 39

1.2.10.1 Materials for Civil Works ............................................................................................................ 39

1.2.10.2 Information for Civil Works ......................................................................................................... 39

1.2.11 Final Information to be Supplied before Contract Completion .................................................. 40

1.3. APPENDICES ....................................................................................................... 41

1.3.1 APPENDIX A – CODES AND STANDARDS ................................................................................... 42

1.3.2 ................................................................................................................................................................. 42

1.3.3 APPENDIX B – ABBREVIATION LIST ............................................................................................ 43

1.3.4 APPENDIX C – SAFETY, HEALTH AND ENVIRONMENTAL ........................................................ 45

1.3.5 APPENDIX D - CORROSION PROTECTION .................................................................................. 47

1.3.6 APPENDIX E - DRAWINGS ............................................................................................................. 48


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1.1. General Requirements

1.1.1 Scope

1.1.1.1 The Development

Ankerlig Power Station is at Atlantis in the Western Cape Province. The project was constructed in

two phases, namely Ankerlig 1 which is 600MWe capacity, 4 x 150MWe gas turbines installed in

separate enclosures and Ankerlig 2 which is 750MWe capacity, 5 x 150MWe gas turbines installed

in one Turbine hall enclosure.

The gas turbines are Siemens SGT5-2000E model which are nominally 150MWe units. The gas

turbines are installed in the form of open cycle and are known as OCGT’s (Open Cycle Gas

Turbines). Eskom generation has identified an urgent need for additional diesel storage tanks at

Ankerlig due to required increased operation of the gas turbines.

The gas turbines were originally installed to operate on Peaking generation, which is morning and

evening peak with the load factor of 3 to 5%. The projected load factor for the gas turbines

operations has gone up to 40% in some months and the existing diesel storage tanks will not meet

with these projected load factors.

This works information is concerned with the additional diesel storage tanks for Ankerlig Power

Station. The additional diesel storage tanks will be considered by the Employer as an extension to

the existing diesel storage system.

1.1.1.2 Permits and Licenses

The Employer is responsible for obtaining all the relevant permits and licenses associated with the

development of the additional diesel storage tanks. The Contractor is responsible for obtaining all

the relevant permits and licenses associated with the construction, installation and commissioning of

the additional storage tanks contract for Ankerlig Power Station.

1.1.1.3 Scope of the Works

The scope of this contract is to carry out the process and mechanical design, manufacture, and

supply, delivery, erection, testing, painting and corrosion protection, commissioning and handover of

storage tanks at Ankerlig Power Station. Tanks are required for the storage of No 2 distillate fuel oil,

and raw fire-fighting water. The scope will be in two lots as follows:

Lot 1 two No 2 distillate fuel oil storage tanks at Atlantis.

Lot 2 one fire water tank at Atlantis.

Civil works including bunds

1.1.1.4 Exclusions

The following Activities are specifically excluded from the works:

Off loading pumps only but not the connecting piping.


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1.1.2 Site Conditions Access and Contractor’s Area

1.1.2.1 Security

The Contractor shall conform to all Site security requirements. Furthermore the Contractor shall be

responsible at all times for the security of his own personnel, equipment and materials and for the

security of their operations within the Site extent.

1.1.2.2 Contractors Compound/Lay-down

A suitable Contractor’s Lay-down Area is made available to the Contractor. The Contractor shall be

responsible for preparing, stoning, servicing and rendering secure such area of this lay-down area,

which he deems necessary for his storage and accommodation requirements.

The Contractor shall provide any covered storage accommodation and Site offices required for his

materials equipment and workforce. The Contractor shall keep his area clean and tidy and shall

remove all waste and surplus material daily.

It is the responsibility of each Contractor to fence its own lay-down area as deemed necessary inside

the Contractor’s lay-down Area. It is the responsibility of the Contractor to determine whether he

requires security for his lay-down Area and provide if required.

The Contractor shall, before commencing work, submit details of all buildings he proposes erecting

in the Contractor’s lay-down Area and the Construction Site for storage, workshop and offices for the

Project Manager’s approval.

At the end of the Contract, the Contractor shall remove all sheds, offices, toilets, surplus materials

etc., remove all temporary connections and leave the Site in a tidy and safe condition.

1.1.2.3 Car Parking

Car parking shall be provided. No car parking shall be permitted in other areas or on Public Roads.

Construction vehicles are allowed on Site however a permit is required from the Project Manager.

For offloading the Contractor shall be confined to its own lay-down area.

1.1.2.4 Roads

The Contractor shall ensure that existing roads are used with due regard to maintaining their current

condition and any damage whatsoever caused by the Contractor shall be immediately repaired to

the satisfaction of the Project Manager.

The Contractor shall take adequate care to ensure no spillage’s occurring onto the public roads

during transportation of materials to/from the Site. Any debris/spillage’s that occur on the public and

Site roads shall be the responsibility of the Contractor and shall be immediately removed/cleaned

up. With regard to prevention of any deposition of muck, dirt etc on roads, the Contractor shall make

all provisions necessary for the cleaning of vehicles leaving the Site.

1.1.2.5 Co-operation with Other Site Service Providers/Good Neighbours Policy

1.1.2.5.1. General

The Contractor shall arrange his operations in such a way as to avoid causing interference and to

minimise disturbance to other staff and to the users of the Site and public roads. The Contractor

shall ensure that the works carried out do not interfere with the operation of the Ankerlig Power

Station except where such interference is deemed unavoidable and is approved by the Project

Manager. Permits will be required for access to the existing Ankerlig 1&2 plants.


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1.1.2.5.2. Other Service Providers

The Contractor’s attention is drawn to the fact that there shall be other service providers who will

require access along routes which will be subject to construction activities. This will require co-

operation with the Project Manager by all relevant parties to ensure that disruption to all contracts is

minimised.

1.1.2.5.3. Good Neighbours

The project has a good neighbour’s policy. This means that any inconvenience caused by the Site

operations to people who work or live in the vicinity shall be minimised.

The Contractor shall take all precautions to avoid the creation of noise, dust, noxious smells,

offensive behaviour or other pollution on the Site. The Project Manager may at his discretion

prohibit any activities, which breach the spirit of this intent.

1.1.2.6 Site Cleanliness

The Contractor shall at all times keep his work and storage areas clean and tidy and at regular

intervals, which shall not exceed a week, shall remove all waste or surplus material and arrange and

pay for disposal off Site. The Contractor shall provide adequate skip facilities around the Site for

waste disposal. The Contractor shall safely clear the Site of temporary structures, surplus material,

equipment, fuel, all liquids and erection equipment and tools on completion.

Where the Contractor fails to meet these requirements, the Employer may remove materials from

Site and charge resultant costs to the Contractor.

1.1.2.7 Working Hours

The Contractor shall comply with the working hours on Site unless otherwise agreed with the Project

Manager.

The working hours for the Site are between the following hours:

06.00 – 18.00 Monday to Friday

06:00 – 13:00 Saturday

1.1.2.8 Industrial Relations

The Contractor shall comply with all local statutory and other labour laws and regulations pertaining

to the Works.

1.1.2.9 First Aid

The Contractor complies with all statutory requirements in addition to the requirements of this

Specification.

1.1.2.10 Manner of Execution - Personnel

During the erection of the Works, the Contractor (or Sub-Contractor) shall pay the wages for any

local labour, skilled or unskilled, employed by him and shall comply with the working hours and

holidays appropriate to the district and with the Basic Conditions of Employment Act.


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1.1.2.11 Contractor's Representatives and Personnel

The Contractor shall appoint a Site Manager from the date of commencement of the Construction

Work on the Site. The Site Manager shall be responsible for the organisation and co-ordination of

the entire installation and shall be authorised to make binding arrangements.

The Contractor should supply a full time safety representative. The Contractor’s Safety

Representative is required to attend all safety meetings on Site.

The Contractor shall provide on the Site adequate changing facilities for his workforce suitably

equipped with lockers, changing facilities and toilets and shall provide for adequate attendance to

maintain the facility.

1.1.3 Statutory Requirements, Codes, Building Regulations

The Contractor shall be required to assume full professional liabilities with regard to fulfilment of any

Statutory Requirements. In this regard, the Contractor is advised to acquaint himself thoroughly with

the local statutory regulations and requirements in the Republic of South Africa together with

relevant data/undertakings contained in the approved documents.

Codes and standards governing the design, construction, commissioning and testing of the Plant

must be accepted by the Project Manager. The Plant and each individual portion thereof must

comply with internationally accepted codes and standards.

In case of conflict between international codes, standards or guidelines and the requirements

specified in this Functional Specification, the more onerous specification takes precedence.

As a minimum requirement the contractor shall comply with all legislation and mandatory codes and

standards.

1.1.4 Project Management

1.1.4.1 General

Further to the NEC requirements the Contractor shall submit a Project Implementation Plan (PIP) for

acceptance which shall not materially deviate from that submitted with the tender. Any deviations will

be subject for acceptance by the Project Manager.

The Contractor shall submit organisation charts to indicate the relationship of the project

management team to the Contractors overall organisation and shall identify the person with overall

responsibility, authority and control. The Contractor shall prepare a Project Management Manual

setting forth the responsibilities and levels of authority within the Project Management Team and

Contractors organisation chart.

Names and curriculum vitae of other key personnel including designers shall be submitted to the

Employer by the Contractor. It is a requirement that the key personnel, in particular, have good

communication skills in the English language. Key personnel shall be appointed to the acceptance of

the Project Manager.

Any Contractor or sub-Contractor personnel deemed by the Project Manager to be incompetent,

negligent or otherwise objectionable shall be removed from the jobsite or design/manufacturing

phase immediately upon the request of the Project Manager. Key personnel shall not be replaced

without the approval of the Project Manager.

It shall be a requirement that key personnel of the Contractor’s Project Management Team provide

continuity in the control of the Works until the end of the warranty period.

Any Contractor or sub-Contractor personnel deemed by the Project Manager to be incompetent,

negligent or otherwise objectionable shall be removed from the jobsite or design/manufacturing


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phase immediately upon the request of the Project Manager. Key personnel shall not be replaced

without the acceptance of the Project Manager.

It shall be a requirement that key personnel of the Contractor’s Project Management Team provide

continuity in the control of the Works until the end of the warranty period.

The Contractor shall prepare and implement a document management system, for receiving,

distributing, and retaining project correspondence, design data, drawings, specifications, instruction/

data books, test reports, progress reports etc.

Data books for each system shall contain the following:

Complete set of as built drawings.

All quality documents.

Completed Quality Control Plans.

All test results (including material mill certificates, welding maps, pump test curves, electrical

equipment tests, etc.)

All equipment specifications.

Operating and maintenance manuals.

The final master document shall be handed over to the Project Manager.

The Contractor shall implement and keep up to date a configuration management plan (including

KKS coding).

1.1.4.2 Contractor’s Representative

The Contractor shall appoint a person at the date of signing the Contract (The Contractor’s

Representative) who will have full responsibility for the complete Works and act as a single point of

contact in all matters on behalf of the Contractor.

The Contractor's Representative shall be responsible for the organisation and co-ordination of the

entire installation and for clarification of all pending installation questions with the Project Manager

and the Contractor's Representative shall be authorised to make binding arrangements.

The Contractor shall supply a full time safety representative who has responsibility for carrying out

all safety tasks. The Contractor’s Safety Representative is required to attend all safety meetings on

site.

1.1.4.3 Competence of Welders and other Personnel

The Contractor (or Sub-Contractor) shall employ, for execution of the Works, only personnel

possessing a level of competence, skill and (where called for) qualification which is adequate for the

tasks assigned to them.

For welding operations each welder shall possess a valid certificate of competence as specified in

the appropriate design or construction code. Before commencing any work on the Site, this

certificate must be produced for inspection by the Employer. The Contractor shall have valid and

current welder qualifications certificates appropriate for the welding to undertaken by each of the

Contractors or subcontractors welders.

1.1.4.4 Welders and Welders Qualification - General

Welders employed on any work under the Contract, either at manufacturers facilities or on site, shall

be proved to be competent to carry out the type and standard of welding required prior to

commencing work. All welders shall be qualified in accordance with EN 287 or approved equivalent,

international standard.


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In the case of pressure parts and pressure part attachment welds, each approved welder shall have

a unique identification number which shall be indicated on all welds made by him and on all

permanent test records applicable to those welds including radiographs.

All welders engaged on either shop or site welding shall be under the supervision of a competent

welding engineer. The Contractor shall submit details of his control procedures for welding, heat

treatment and non-destructive testing as part of the quality control procedures.

1.1.4.5 Welders’ Test

Sample welds shall be carried out on specimens of similar shape, thickness and chemical analysis

to the material to be welded, and in a position which shall represent as far as possible the worst

conditions under which actual welding will take place. The method of preparation of the test pieces,

and the standards to be used in examination of them shall be according to the agreed Standard or

Codes, or as may be agreed with the Employer’s Representative. All expenses in connection with

welder's tests shall be borne by the Contractor. The range of approval shall cover all welds to be

undertaken by the welders.

1.1.4.6 Programming

The Contractor shall appoint a fully experienced scheduler competent in the use of Primavera P5 to

undertake all programming for the complete Works for the period of the contract. The scheduler will

transfer to site and be located on site during the installation and commissioning of the plant.

Programming shall be in accordance with Clause 31 of the NEC Engineering and Construction

Contract.

The Contractor shall furnish a detailed programme and critical path analysis indicating each

separate operation in the works. The Contractor’s programme and critical path analysis shall be

processed at least monthly throughout the Contract.

In addition, the Contractor shall furnish to the Project Manager each week a detailed statement of

the work he proposes to carry out each day of the following week.

1.1.4.7 Progress Reports

The Contractor shall be required to furnish progress reports in accordance with Clause 32 of the

NEC Engineering and Construction Contract. In addition, the Contractor shall be required from time

to time to estimate final and intermediate (e.g. delivery) dates. Relevant photographs of construction

progress shall be included with the Project Report.

The progress of the entire project will be controlled using a critical path analysis programme.

The Contractor will be required to furnish weekly and monthly progress reports against approved

programmes, in a format approved by the Project Manager.

1.1.4.8 Progress Meetings

The Contractor shall be required to have regular progress meetings at intervals to be agreed, but at

a minimum of monthly with the Project Manager.

During the design, engineering, procurement and manufacturing phases, progress and design

review/clarification meetings shall be held with the Project Manager on an as needed basis, but as a

minimum once a month.

When construction / commissioning activities commence, progress meetings shall be held monthly

on Site, supplemented by weekly (or as required) site meetings to review progress and

measurements of site activities. The Contractor shall appoint an experienced planner to the Site

from commencement of construction on Site for the duration of major construction work.


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At any stage during the Contract special meetings may be arranged as necessary to resolve any

technical or commercial issues. Each party shall pay their own travel and accommodation expenses

for the meetings.

It is the Contractors responsibility to organise Progress Meetings and to issue Minutes of Meeting.

1.1.4.9 Project Documentation

1.1.4.9.1. Submission of Project Documentation

The Contractor shall provide within one (1) month from the Contract Date a complete time schedule

for submission of all documentation including drawings, methodologies, design calculations,

schematics, wiring tables/diagrams, manuals, procedures and any other information.

It is an essential requirement that all documentation and any other information shall be submitted to

the Project Manager at a specified date and in sufficient time for acceptance before proceeding with

the relevant part of the work. In particular all drawings, operating philosophy, control philosophy,

design philosophies and design calculations shall be submitted at regular intervals to ensure a

steady flow of submissions. Acceptance may be delayed if large quantities of documentation are

submitted at the one time.

Acceptance by the Project Manager will not relieve the Contractor of his obligation to meet all the

requirements of the Contract or relieve the Contractor of his responsibility for adequacy of design

calculations and drawings and other documentation.

All project documentation shall be transmitted electronically in addition to three hardcopies.

If the Contractor provides drawings which are common to multiple units / systems / items of plant the

Contractor shall put in place a programme to ensure that any differences are highlighted and

documented on all relevant drawings (including as-built), procedures & instructions specific to each

unit.

Configuration management will be implemented to ensure that all documents are kept up to date and

reflect the as-is and as-built status.

1.1.4.10 Drawings

1.1.4.10.1. Contract Drawings

Three (3) hardcopies of all drawings plus one (1) electronic copy shall be submitted in sufficient time

to permit comment and/or modifications being made without delaying the Contract Delivery and

Completion Dates. For key drawings, the Project Manager reserves the right to request additional

copies.

Within one (1) month of Contract Date, the Contractor shall submit a detailed Master Drawing

Schedule in EXCEL or other approved format, showing each drawing, including subcontractors’

drawings, and the date for submission of these drawings for acceptance by the Project Manager.

Columns will be provided in this schedule for the following information:

Date of submission to the Project Manager.

Date on which Project Manager Comments are received.

Dates of re-submission and further comments if applicable.

Dates on which drawings issued for construction.

Dates on which drawings subsequently revised.

Date on which drawings issued in as-built form.


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This Master Drawing Schedule shall be updated and submitted to the Project Manager for

acceptance. A copy of the updated Master Drawing Schedule shall be included with the Progress

Report.

Following completion of construction of the tanks the Contractor shall submit “As–built” drawings for

the Project Manager’s acceptance. The accepted drawings shall be duly stamped “As-built”.

1.1.4.10.2. Construction Drawings

Construction drawings shall include fully dimensioned arrangement and detail drawings giving the

design code, operational and design pressure and temperature and the ratings, scantlings and

materials of all components. Weld details and applicable WPS shall be included and any specific

construction and manufacturing procedures. All non destructive examination and hydrostatic testing

requirements shall also be given.

1.1.4.10.3. Preparation and Format

All drawings supplied under the Contract shall have titles and explanatory notes in English. In

addition, English translations of any Standard, Specification or Document related to the design,

production, inspection or testing of any part of the Works shall be supplied.

The drawings shall be prepared in accordance with a recognised international or national standard

and include a title block accepted by the Project Manager. For hard copies of drawings ISO “A”

sizes shall be adhered to and except in special circumstances, sizes larger than “A1” shall not be

used.

Drawings shall preferably be supplied in Microstation format and copies of all drawings shall be

provided on CD-ROM or other suitable computer media.

1.1.4.11 Calculations

1.1.4.11.1. Submission of Calculations

All design calculations shall be submitted to the Employer for information.

1.1.4.11.2. Presentation of Calculations

Calculations must be comprehensive, coherent and suitably referenced to information sources and

cross referenced within themselves. All calculations, other than computer printout, shall be on A4

size paper properly bound. Each book of calculations shall have a title page. The title page shall

indicate clearly:

Contractor’s name.

Project name.

Designer’s name.

Checker’s name.

Contract number.

Calculation title.

Assumptions used for design purposes including reference to Basic Design Criteria Document.


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Codes and Standards used.

Loadings used (where applicable).

Date of Calculation.

Calculation.

Reference sources

Manufacturer’s names and literature.

Reference to the appropriate drawing.

Technical specification section and paragraph number.

Control register reference as applicable.

Date of issue.

The title page shall also provide for the recording of any revisions (and dates) to the calculations.

Calculations shall be in English and in SI units, clearly legible, preferably typed and bound in stiff-

backed ring binders. Calculations which are not easily legible or which present difficulty in

comprehension will not be accepted by the Project Manager and the Contractor shall be obliged to

resubmit such calculations in legible/comprehensible form for acceptance by the Project Manager.

The Contractor shall provide a master design schedule in Microsoft Excel format which will be

updated on a monthly basis. It will have columns showing dates for submission by the Contractor

and comments by the Project Manager as required in Sub-section 1.1.4.10 for Calculations. A copy

of the updated Master Design Schedule shall be included with the Progress Report.

1.1.4.12 Manuals

The Contractor shall provide four (4) hardcopy sets of the manuals for each station to enable the

Project Manager to comment and request changes as necessary. Copies of all Manuals shall also

be provided on CD-ROM or other suitable computer media marked for review. The final version (as

built) of all Operations and Maintenance (O&M) manuals shall be provided four (4) months after

taking over of the plant, marked final version.

In all cases, and irrespective of hard copies supplied, electronic copies of manuals are required in a

Microsoft / .pdf format suitable for use with Eskom’s user software standards.

All manuals shall be divided by systems or sections and cross indexed as necessary.

The number of copies required is four (4).

The manuals are complete with:

power station name and order number;

content list;

list of reference drawings;

details of all components

The manuals are submitted in loose-leaf binders to ISO format and normally A4 size. The use of

oversize pages is kept to a minimum and does not exceed page height unfolded. Fixings are


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preferably “D” ring and are of the snap close type. Post binders or other fixings are not acceptable.

Binders do not exceed 80mm in overall thickness. The document identity appears on both the front

cover and on the spine.

Manuals are of good quality prepared by suitably experienced personnel and contain general

arrangement drawings, installation drawings and instructions, operating and maintenance

instructions for all components, detailed parts lists which are accompanied by exploded view type

drawings clearly detailing the part and uniquely identifying it, technical descriptions of the plant and

material and component parts, spare part ordering instructions and type test certificates. Any special

instructions pertaining to storage of spare parts or to their shelf life are included in the manual.

All drawings required for component location, dismantling, and re-assembly for maintenance is

provided in the manual. All special tools required for maintaining and operating the plant and

material are identified in a schedule and described in the manual.

Manuals are produced such that a Synopsis is first presented, followed by a First Draft, then a pre-

print Proof and finally by the Approved Manual. The required documents are submitted for

acceptance on the dates as shown in the key date schedule.

1.1.4.12.1. Design Manual

This manual shall contain all the design calculations and all equipment and system data sheets and

design criteria required under the Contract.

1.1.4.12.2. Construction Manual

This shall include a comprehensive record of as built site construction tests and records. The

manual(s) shall be compiled in separate parts to reflect the plant and services supplied.

1.1.4.12.3. Commissioning Manual

This manual shall include all the records, certificates and test results arising from the agreed pre-

commissioning and commissioning procedures carried out on site. The performance tests and

guarantee test results shall also be included. There is a particular requirement that all commissioned

plant/equipment values be recorded in this manual and subsequently incorporated into the final

version of O&M manuals.

1.1.4.12.4. Quality Assurance Manual (QAM)

Refer to section 1.1.6.3 in this document.

1.1.4.12.5. Quality Control Records/Manual

Refer to section 1.1.6.7 in this document.

1.1.4.13 Plant Identification System

A common alphanumeric designation system for the codification of all items of plant, equipment and

components shall be used for the whole power station. The coding system is based on the

“Kraftwerk Kennzeichen-System” (KKS), as developed by the VGB (Germany) and adapted for

Eskom. The Contractor shall be responsible for ensuring that he is fully familiar and compliant with

the standards and concepts of the KKS system as applied by Eskom.


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The Contractor shall be responsible for the codification of all plant, equipment and components in his

supply for which he is responsible in terms of engineering and design.

The specific KKS-code of each item of plant, equipment, component, measuring points, junction box,

cable, etc., shall appear on all documents, instruction manuals, schedules, drawings (i.e. flow

diagrams, general arrangement, schematic diagrams, cable block diagrams, etc.) and labels for

plant, equipment and components.

A list of all KKS codes used by the Contractor shall be provided in accordance with Eskom standard

documentation. The relevant KKS-code shall be included on the label according to the required

Eskom standard format.

The allocation of all codes shall be to Eskom approval. The Contractor shall ensure that the code is

applied in a uniform and consistent way and that all codes allocated are unique.

1.1.4.14 Procedures

1.1.4.14.1. Weld Procedures, Specifications and Documentation

For all pressure pipelines, containment vessels, and structural welded items, the Contractor shall

submit to the Project Manager for comment, the following documents prior to commencement of

welding:

Welding Procedure Specification (WPS).

Weld Procedure Approval Records (WPAR).

Welder Qualification Records (WQR).

Pre- and Post- Weld Heat Treatment where applicable.

Inspection Schedule including Quality Assurance and Quality Control Requirements.

Third party inspection authorities and / or authorised bodies.

Non-destructive Examination and Testing Procedures.

Standard Weld Repair Procedures.

All welding procedures including those proposed in repair situations shall be qualified as required

EN288 or approved equivalent and all qualified procedures shall be submitted to the Project

Manager for acceptance prior to the commencement of any welding.

Tube ends shall be prepared in accordance with an internationally recognised standard for welding

tube to tube, tube to wall and tube to headers, etc.

Inspection records will be stored on site and available in a coherent and traceable manner when

required.

1.1.4.14.2. Welding Electrodes and Consumables

Before any welding is commenced, the Contractor shall submit a list of all electrodes and

consumables to be used, to the Project Manager for acceptance. In each case, the appropriate DIN,

BS, ASTM or equivalent designation together with the proprietary brand name shall be given.

Welding electrodes shall be suitably stored before use.


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1.1.4.14.3. Site Welding

The Contractor shall be required to establish the procedures and conduct the tests, or provide the

evidence required, according to the agreed Welding Code to qualify the procedures, for use with the

agreed Construction Code and the welders for the application of the procedures.

1.1.4.14.4. Erection Procedures

The Contractor shall submit four (4) sets of the erection procedures for each tank to the Employer for

information so as to allow the Project Manager to comment one (1) month prior to the referenced

erection commencing on Site.

1.1.4.14.5. Pre-Commissioning and Commissioning Procedures

The Contractor shall prepare four (4) sets detailed testing and pre-commissioning procedures to

cover the period from completion of erection to ready to start-up and all commissioning tests and

procedures to be carried out to achieve readiness for performance testing. These procedures shall

be submitted to the Project Manager two (2) months prior to commencement of the pre-

commissioning.

1.1.4.14.6. Performance and Guarantee Tests Procedures

The Contractor shall submit the performance and guarantee tests procedures to the Employer for

comment, at a date to be agreed, but not less than two (2) months prior to start of commissioning.

1.1.4.15 Inspection and Tests

1.1.4.15.1. Materials

All construction materials will be new and clean and will be free from rust and pitting and the cast

numbers will be clearly marked. Material cast numbers will be checked for compliance with the

material certificate and the requirements stipulated on the drawings.

Manufacturer’s material certificates of chemical analysis and mechanical properties shall be

submitted for all material used in the Works or as otherwise accepted by the Project Manager.

Materials are to be accepted by the Project Manager. Where a test piece fails to comply with the

relevant material specification or the material cast number indicates a material not compliant with the

material stipulated on the drawings the Project Manager reserves the right to reject the whole of

such material. Materials proposed for use are subject to the approval of the Project Manager. The

Project Manager may reject the materials at his absolute discretion.

1.1.4.15.2. Inspection of Welding

The extent of weld inspection, the final weld quality, and the method of examination shall be as

stated in the agreed Standards or Codes. All welding inspection shall be performed by Welding

Inspectors that are qualified to perform inspections. The Contractor shall maintain, both at the

manufacturer facilities and on site, adequately indexed records of all welding, weld inspection and

repairs which shall be available to the Project Manager, together with light box facilities and dark

room for viewing of X-ray radiographs.


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1.1.4.15.3. Weld Repairs

The Contractor shall immediately advise the Project Manager of any repair required on the Works.

Where such repairs are found to be necessary by welding, dimensioned sketches of the excavated

areas shall be prepared and the proposed repair procedures submitted for acceptance by the Project

Manager before any repair is undertaken.

In the case of weld cracking, the Project Manager shall require a full investigation to be made to

establish the cause of cracking. No repair work or removal of the evidence shall be undertaken prior

to acceptance of the repair procedures by the Project Manager. The cost of all such investigations

and reports shall be wholly borne by the Contractor.

1.1.4.15.4. Non-Destructive Tests

All welds shall be tested in accordance with the relevant standards accepted by the Project

Manager. This is a minimum requirement and in no way limits the Contractor’s overall responsibility

for quality of fabrication.

1.1.4.15.5. Pressure Tests

The Contractor shall hydraulically test all parts subjected to internal pressure under normal or

abnormal working conditions after satisfactory completion of the other non-destructive tests in

accordance with the applicable codes. The Contractor shall be required to perform a Hydro-test and

shall include all fittings and hoses for this purpose.

Hydraulic test pressures quoted shall in all cases be the difference between internal and external

pressures and in each test, the test pressure shall be maintained for sufficient duration to allow a

thorough inspection of all seams, joints and connections; but in no case shall a test of less than that

specified in the API650 standard. The Contractor will supply all equipment, suitably calibrated, to

perform these tests. Water will be made available to the Contractor for the purpose of the hydro-test.

The contractor shall demarcate and appropriately make safe the area surrounding the tank during

hydraulic tests.

A hydro-test procedure and programme will be submitted to the Project Manager for acceptance

prior to a test being carried out.

1.1.4.15.6. Low Pressure Pneumatic Leak Testing

The Contractor shall include for pneumatic testing of all reinforcement plates used.

1.1.4.15.7. Third Party Inspection

The Contractor shall provide for a third party inspection of pressure systems. This inspection should

include for the review of the design, welding and erection procedures and a review of the NDT

results of the welds. The third party Inspection Company should provide certification that the work is

complete, to their satisfaction and meets all statutory requirements.

1.1.5 Site Services

1.1.5.1 General

The Contractor shall provide all necessary services at the required locations.


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1.1.5.2 Water Supply

The Employer will provide a construction water supply at a source within the Site boundary The

Contractor shall be entirely responsible for providing his own water supplies in the Contractor’s Area.

It is the responsibility of the Contractor to make an agreement with the Employer for the supply of

water to the Contractor’s Area.

1.1.5.3 Telephone/Fax

The Contractor shall be entirely responsible for providing his telephone connection in the

Contractor’s Site office area The Contractor shall bear all charges associated therewith including

payments for the supply of services.

1.1.5.4 Power Supply

The Employer will provide a construction power supply to the site boundary. The Contractor shall be

entirely responsible connecting to this source and routing the cables as required by the Project

Manager. The Contractor shall indicate the extent of supply required.

The Contractor shall bear all charges associated therewith including payments for the supply of

services.

All wiring and electrical work carried out by or on behalf of the Contractor shall conform to the

Employer's regulations, be maintained in a proper condition, and be to the satisfaction of the Project

Manager.

1.1.5.5 Sewage System

The Employer will provide appropriate connection to the sewerage system in the site area.

1.1.5.6 Washing and Sanitary Facilities

The Contractor will provide all provisions necessary for washing and sanitary facilities to conform to

Statutory Health and Safety requirements.

1.1.5.7 Fire Fighting

The Contractor shall provide adequate fire fighting provisions for their construction area. Fire

extinguishers shall be provided by the Contractor in the work areas and his staff shall be trained in

their use. The Contractor shall comply with recommendations provided in NFPA 850 for fire

protection during construction.

The Contractor shall ensure that there is no interference by his employees or by his sub-Contractors

with the ring main and equipment other than for use in fire fighting. He shall arrange that in all areas

under his control the recommended type of fire extinguishers shall be properly identified by suitable

markers and regularly serviced.

1.1.5.8 Personal Protection Equipment

Protective equipment of an appropriate type and standard shall be worn by all persons without

exception while on site. Minimum shall include safety helmet and footwear, and, where necessary,

ear protectors and eye protection glasses.


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1.1.6 Quality Assurance

1.1.6.1 General

The Contractor shall for all the Works to be performed have established and implement quality

assurance arrangements which meet the requirements set out in the International Standard ISO

9001:2000 “Quality Management System, which shall include, in a transparent manner, the quality

assurance and quality control of its sub-contractors during all phases of the Contract, including,

Design and Engineering, manufacturing, Site Construction, Erection, Commissioning and Start-up.

The Contractor shall check all parts of the Works before dispatch from the manufacturing facilities to

ensure that all materials, dimensions and tolerances are in accordance with certified drawings and

mill certificates.

1.1.6.2 Quality Assurance, Concept and Control

This section provides the minimum requirements for establishing and implementing a quality

assurance programme which is applied to all aspects of the work necessary for carrying out the

Contract.

The scope of this section extends to material parts, components, systems and services as a means

of obtaining and sustaining the reliability of critical items, operating capacity and availability. If the

Contractor’s programme does not cover the quality assurance requirements as indicated in this

section then he must state, together with documentary evidence, the reason why the requirements

do not apply.

Acceptance of the Contractor’s quality assurance programme does not relieve the Contractor’s

obligation to comply with the requirement of the Contract. If the programme is found to be ineffective

or inadequate in providing for quality assurance or control, then the Project Manager reserves the

right to request for necessary revisions of the programme.

The Contractor is required to produce readily identifiable documentary evidence covering the extent

and details of both his own and his subcontractor’s quality assurance system.

The documentary evidence should take the following form:

Quality Assurance Manual (QAM)

Works (Manufacturer’s Facility) Quality Assurance Programme (WQAP)

Site Quality Assurance Programme (SQAP)

Project Specific Quality Plan (PSQP)

While acknowledging that the Contractor may combine the QAM, WQAP and SQAP as one

document, it is a specific requirement of this Specification that these documents are prepared

separately and submitted to the Project Manager.

1.1.6.3 Quality Assurance Manual (QAM)

The QAM shall be a general comprehensive document outlining the Contractor's basic organisation,

policies and procedures. The information to be given in the QAM shall include but not be limited to:

Quality policy

Quality assurance programme

Organisation structure showing inter-relationships

Functional responsibilities and levels of authority


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Lines of communication

Customer relations

Laboratory facilities

Design review

1.1.6.4 Works (Manufacturer’s Facilities) Quality Assurance Programme (WQAP)

The WQAP shall detail the Contractor's quality assurance programme at Works applicable

throughout all phases of Contract performance including design, procurement, manufacture,

inspection and testing. It shall identify each of the programme elements to be designed, developed,

executed and maintained by the Contractor for the purpose of ensuring that all supplies and services

comply with this Specification including the Employers requirements.

The information to be given in the WQAP shall include typically:

Organisation and responsibility

Design and document control

Procurement control

Control on sub-Contractors

In-process quality control

Welding quality control

Heat treatment control

Inspection and testing

Control of non-conformances

Corrective action

Control of inspection, measuring and test equipment

Handling, storage and delivery

Records

Quality audits

1.1.6.5 Site Quality Assurance Programme (SQAP)

The SQAP shall detail the Contractor's Quality Assurance Programme at Site applicable throughout

site construction, erection and commissioning. It is the underlying philosophy of this Specification

that the quality built into the product at Works shall be maintained throughout the construction and

commissioning stages. The quality and workmanship shall be consistent with the design life of the

Works.

While, in principle, the SQAP shall include the items listed in WQAP, it shall, however be

approached differently to take into account site conditions.

The SQAP shall include typically:

Organisation and Responsibility.


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Control of Drawings and Documentation.

Site Activities Checklists.

Cleaning and protection procedures.

Health and Safety management procedures and records.

Receipt Inspection of Materials at Site.

Material Storage Control.

Issue of Materials and Consumables.

Inspection and testing Procedures.

Welding Quality Control.

Non-Destructive Testing.

Heat Treatment Control.

Control of Painting and Insulation Works.

Earthworks control checks and testing.

Concrete Quality Control incl. all test results.

Pre-commissioning.

Commissioning.

Corrective Action.

Control of Inspection, Measuring and Test Equipment.

Records.

Quality Audits.

1.1.6.6 Project Specific Quality Plan (PSQP)

The Contractor is required to prepare manufacturing and site construction / erection quality plans for

all plant items and services provided under the Contract based on the Contractor's standard quality

assurance procedures. The quality plan shall also define the involvement of the Contractor, the

Project Manager and or his inspection authority in the inspection and test programmes.

The Project Specific Quality Plan (PSQP) shall incorporate typically:

Charts indicating flow of materials, parts and components through manufacturing quality control,

inspection and test to delivery and site erection quality control, inspection and test.

The Charts shall indicate the location of hold points for quality control, inspection and test

beyond which manufacture and site erection shall not continue until the action required by the

hold point is met and the documentation required is generated.

Document control procedure.

An indication of the organisations responsible for the quality activities covered and the

responsibilities of the quality assurance personnel.


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Reference to quality assurance procedures, goods inward procedures and non-conformance

procedures, etc.

The Contractor shall review and submit his sub-Contractor's quality plans and include these in the

PSQP. The Contractor shall determine and agree with the Project Manager the control to be

exercised over the sub-Contractors and the degree of surveillance that shall take place.

Provision shall be made for the Project Manager to insert hold points at which quality control

activities are to be witnessed by the Project Manager himself or his appointed inspecting authority.

The Contractor shall furnish the Project Specific Quality Plan (PSQP) not later than one (1) month

prior to the start of manufacture. The PSQP shall define the Contractor's organisation and

responsibilities of all management including quality assurance personnel and shall detail the

procedures the Contractor intends to use to manage and control those aspects of the Works which

may affect the quality of the completed installation.

The PSQP as revised to incorporate any comments of the Project Manager shall be considered as

forming part of the Contract and any subsequent changes must be agreed in writing by the Project

Manager prior to implementation.

The Contractor shall implement effective planning, resourcing and control of all contracted activities

by the implementation of the PSQP and associated work instructions.

The Contractor shall identify its verification requirements on the PSQP submitted to the Project

Manager for acceptance and shall identify the following:

Stages subject to random surveillance,

Inspections to be witnessed,

Hold points beyond which work cannot proceed before completion of all verification and

related activities.

The Contractor shall establish measures for the identification and control of materials and

components throughout all stages of the Contract.

The Contractor shall be responsible for identifying and arranging any verification activities requiring

statutory approval in the country of manufacture.

1.1.6.7 Quality Control Records/Manual

The Contractor shall maintain and provide at the end of manufacture and Works testing a manual or

manuals including copies of all formal certificates, reports and results of tests and inspections

related to the plant covered by the specification. This manual shall contain the approved Works

certification documentation for all Plant, Equipment and services as specified in the relevant codes

and standards and in this specification and the Contractors Quality Manual. This manual shall also

include all mill and material test certificates. Certificates and test procedures shall be specific to the

Plant supplied. Weld procedure and welder qualification certificates shall also be included. Three

sets shall be provided.

1.1.6.8 Monitoring by the Employer

The Project Manager reserves the right to review and amend the proposed verification arrangements

in cases where these arrangements have not been agreed prior to the order date between the

Contractor and any Sub-Contractor / Supplier.

During the course of the Contract the Project Manager reserves the right to monitor the

implementation of the Contractors quality assurance arrangements including those of the Sub-

Contractors; where non conformances are identified the Contractor shall implement agreed


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corrective actions. The Project Manager shall be afforded unrestricted access to review the

implementation of the corrective actions. A programme shall be established for all such audits.

1.1.6.9 Site

For Site work the Project Manager shall monitor all aspects of the Contractors daily work including

his control of Sub-Contractors in accordance with the agreed procedures, compliance with Codes

and Standards and the Specification, Construction Health and Safety plan and the achievement of

milestone dates for the discrete work packages.

1.1.7 Safety

1.1.7.1 Contractor’s Obligations

In carrying out its obligations to the Employer in terms of this contract; in providing the Works; in

using Plant, Materials and Equipment; and while at the Site for any reason, the Contractor complies

and procures and ensures the compliance by its employees, agents, Subcontractors and

mandataries with:

the provisions of the Occupational Health and Safety Act 85 of 1993 (as amended) and all

regulations in force from time to time in terms of that Act (“the OHSA”); and

South African Building Codes and Construction Regulations 25207 of 2003; and

Labour Relations Act; and

the Eskom “Safety, Health and Environmental Requirements for Contractors” document attached

to the Works Information (as amended from time to time) and such other Eskom Safety

Regulations as are applicable to the Works and are provided in writing to the Contractor

(collectively “the Eskom Regulations”). The Eskom Regulations may be amended from time to

time by the Employer and all amendments will be provided in writing to the Contractor. The

Contractor complies with the provisions of the latest written version of the Eskom Regulations

with which it has been provided; and

the health and safety plan prepared by the Contractor in accordance with the SHEQ

Requirements.

(The OHSA and the Eskom Regulations are collectively referred to as the “SHEQ Requirements”.)

The Contractor, at all times, considers itself to be the “Employer” for the purposes of the OHSA and

shall not consider itself under the supervision or management of the Employer with regard to

compliance with the SHEQ Requirements, the Contractor shall furthermore not consider itself to be a

subordinate or under the supervision of the Employer in respect of these matters. The Contractor is

at all times responsible for the supervision of its employees, agents, Subcontractors and

mandataries and takes full responsibility and accountability for ensuring they are competent, aware

of the SHEQ Requirements and execute the Works in accordance with the SHEQ Requirements.

The Contractor ensures that all statutory appointments and appointments required by any Eskom

Regulations are made and that all appointees fully understand their responsibilities and are trained

and competent to execute their duties. The Contractor supervises the execution of their duties by all

such appointees.

The Employer, or any person appointed by the Employer, may, at any stage during the currency of

this contract:

conduct health and safety audits regarding all aspects of compliance with the SHEQ

Requirements, at any off-site place of work, or the site establishment of the Contractor;


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refuse any employee, Subcontractor or agent of the Contractor access to the premises if such

person has been found to commit an unsafe act or any unsafe working practice or is found not to

be qualified or authorised in terms of the SHEQ Requirements;

issue the Contractor with a stop order should the Employer become aware of any unsafe

working procedure or condition or any non-compliance with any provision of the SHEQ

Requirements.

The Contractor immediately reports any disabling injury as well as any threat to health or safety of

which it becomes aware at the Works or on the Site to the Project Manager.

The Contractor appoints a person, qualified in accordance with the SHEQ Requirements, as the

liaison with the Eskom Safety Officer for all matters related to health and safety, this person shall be

contactable 24 hours a day.

The Contractor confirms that it has been provided with sufficient written information regarding the

health and safety arrangements and procedures applicable to the Works to ensure compliance by it

and all employees, agents, Subcontractors or mandataries with the SHEQ Requirements while

providing the Works in terms of this contract. As such, the Contractor confirms that this contract and

the relevant Eskom Regulations referred to in this contract constitute written arrangements and

procedures between the Contractor and the Employer regarding health and safety for the purposes

of section 37(2) of the OHSA.

The Contractor agrees that the Employer is relieved of any and all of its responsibilities and liabilities

in terms of Section 37(1) of OHSA in respect of any acts or omissions of the Contractor, and the

Contractor’s employees, agents or Subcontractors, to the extent permitted by the OHSA.

The Contractor hereby indemnifies the Employer and holds the Employer harmless in respect of any

and all loss, costs, claims, demands, liabilities, damage, penalties or expense that may be made

against the Employer and/or suffered or incurred by the Employer (as the case may be) as a result

of, any failure of the Contractor, its employees, agents, Subcontractors and/or mandataries to

comply with their obligations in terms of this clause 18, and/or the failure of the Employer to procure

the compliance by the Contractor , its employees, agents, subcontractors and/or mandataries with

their responsibilities and/or obligations in terms of or arising from the OHSA.

The Contractor shall ensure that all statutory, legislative codes and regulations relating to South

African and Eskom’s Safety, Health and Environmental Policies and Procedures are adhered to

during the design, manufacture, construction and operation of the plant up to Take Over.

The Contractor shall be required to administer and control site activities in such a manner as to

achieve and maintain the safety of all persons on the Site, including employees, visitors and all sub-

contractors.

The Contractor shall make provision on all equipment, mechanical and electrical, for the placing of

locks for the purpose of isolation in accordance with procedures to be agreed with the Project

Manager.

The Contractor shall also comply with the Project Manager’s reasonable recommendations

regarding the temporary or permanent arrangement of ladders, gangways, working platforms,

fencing of openings, posting of warning signs and the wearing of appropriate safety equipment such

as safety harnesses, ear defenders etc. The wearing of safety glasses, safety helmets and safety

footwear at all times by all members of the workforce including management and visitors shall be

compulsory on the Site. These stipulations shall in no way release the Contractor from any

obligations under Occupational Health and Safety Legislation and this Contract.

A Site Safety Advisor will be appointed by the Employer and this person will act for the Employer in

an advisory capacity on all matters affecting the safety of all personnel engaged on the Site.


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1.1.7.1.1. Safety Surveillance Contract Requirements.

The Contractor shall have at least one full time experienced safety officer present on the

construction site at all times during construction. The safety officers shall be suitably qualified by

experience and training and shall be fully knowledgeable in South African Regulations and qualified

with an technical engineering qualification, and a minimum 5 years experience in heavy construction.

The safety officers brief shall be to advise the Contractor in matters of safety, to exercise general

supervision of the observance of safety requirements and to promote safe methods of work. The

Safety Officer Role shall be staffed by an adequate number of persons all qualified as stated above,

to effectively carry out the required safety duties in a timely and effective manner. CV’s for all safety

officers shall be submitted to the Employer for acceptance.

1.1.7.1.2. Safety and Health Plan

Before commencement of any activities on Site the Contractor shall prepare a detailed Safety and

Health Plan for the Project (to include all subcontractors activities), which shall be submitted to the

Project Manager for acceptance. Hard copies of the Safety and Health Plan revised in accordance

with the Employer’s comments shall be available on site before any work commences and all

subcontractors shall have signed that they have received and are familiar with the Safety and Health

Plan.

Detail included in the Safety and Health Plan shall include but not be limited to the following:

standard safe work practices,

identification of hazards including mitigation measures,

personnel protective equipment requirements,

plant inventory including certification,

inventory of employees including record of national safe training certification,

safety inductions (persons, workforce or visitors, shall not be permitted to enter the

construction site(s) unless they have been registered as having received the specific site

safety induction).

emergency evacuation procedures including muster points,

inventory of toolbox talks and attendees,

site safety incentive scheme details,

instructions to site security,

swipe card system (in place from day one (1)),

induction times,

induction training facility,

foreseeable risk assessment (for particular risks i.e. designation of confined spaces etc),

definitions of working-at-height requirements,

car parking external to site,

delineation/ongoing management of lay-down,

consultation arrangements weekly /monthly,

site progress meetings (health and safety No 1 on Agenda),

safety committee meetings (frequency agenda and persons attending),

safe working procedures,


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site perimeters,

speed limit,

waste management (designated skip area),

readily identifiable clean up crew for contractor interface management,

general site illumination and provision for change,

general site signage.

The Plan shall indicate the Contractor’s requirements for new contractors coming to site, Insurances,

site specific safety statements, training matrix (national accredited skills training certification )

proposed lay-down area etc.

The Project Safety and Health Plan must address commissioning activities and develop

commissioning safety rules and established plant tagging, locking systems to ensure safety and well

being of all on Site. This element will be synopsised and included in induction training for all

operatives coming to site.

1.1.7.1.3. Method Statements Risk Assessments (MSRA)

Each different work activity must have a MSRA. MSRAs will be produced by a competent member of

the Contractor’s team before being passed on to the Contractor’s safety office. Commencement of

any work activity shall not take place unless a MSRA including risk mitigation has been submitted to

the Project Manager, five working days in advance of any proposed commencement of the specific

activity. They must be site and task specific, clear and signed off by those undertaking the task and

each MSRA should be posted local to each activity.

1.1.7.1.4. Log of MSRAs

At contract signing a schedule of foreseeable risks must be tied into a specific list or log up front. A

monthly update of such a log must be emailed (supported by a facsimile) to the Project Manager.

1.1.7.1.5. Extent of Subcontracting

The approval of sub-vendors by the Contractor must be subject to the same Health and Safety

Criteria covered herein.

1.1.7.1.6. Safety File

The Contractor shall provide or procure information for and prepare a Safety File.

The Contractor shall provide a preliminary index of what is expected to go into the Safety File.

As a minimum the Safety File shall contain all of the following:

Design records relating to safety.

As-built drawings of the completed plant and site.

As-built process and instrumentation drawings.

Records of control and instrumentation system logic and settings.

Non-destructive test records.

Commissioning records for all plant proving fitness for purpose.


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Statutory certificates for all boilers, steam receivers, steam containers, air receivers, lifting

appliances and lifting gear.

Operating and maintenance instructions for all plant and systems.

An inventory of all hazardous substances on the plant along with all necessary safety

information for the substances involved.

Clearance certification where hazardous waste has been removed from the site.

The Employer’s site teams will review progress on a weekly basis starting at commencement of

work.

The completed Safety File, which is required to be handed over to the Project Manager on Take

Over, shall be provided in electronic form.


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1.2. Technical Requirements

1.2.1 Metrological Site Conditions

The equipment shall be designed as outdoor plant and the appropriate meteorological data is

included in Part 5.2 - Climatic Design Conditions.

1.2.2 Working Arrangements

1.2.2.1 Planning of Work

Work must be planned carefully and in particular in case of the fuel oil storage tanks expeditiously. It

would be required that the roof of the fuel tank be placed as soon as possible to reduce the risk of

wind damage to the tank during construction. The contractor shall consider the method of

construction such as installing the roof first tank and installing the strakes from the roof by jacking

the tank upwards. All precautions necessary to ensure safety of personnel and security of supplies

must be taken.

1.2.2.2 Protection of the shell during erection

The Contractor shall employ suitable methods for the protection of the shell during erection to be

agreed with the Project Manager. Full details of these methods shall be made available for the

Project Manager’s acceptance. The factors to be taken into account when determining the suitability

of the protection shall be:

Tank size

Construction methods

Location and degree of exposure to wind loads

Number and type of key plate equipment

Metrological data during all periods of erection

Note: The use of steel wire guys or cables may not necessarily be adequate and consideration

should be given to the use of temporary wind girders

1.2.3 Storage Tanks

1.2.3.1 Terminal Points

Low level nozzles at nozzle flanges and isolating valve.

High level or roof mounted pipe-work routed terminal points 1m above tank base with

nozzle flanges and isolating valve.

Supports for cable trays including to roof instruments

Foundations – Contractor to advise his requirements for the tank foundations in his

Contract documentation to the Employer.

1.2.3.2 Design Parameters

The diesel fuel oil and water storage system shall be supplied consisting of storage tanks as

described herein and shall be in accordance with Part 2.4 Schedule C (Tank sizing). All tank roofs


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should be self supporting in accordance with the applicable code of construction. The tanks shall be

designed to last a minimum of 20 years. The Contractor’s scope of supply of the storage tanks must

include the mechanical and process design.

The Contractor shall assume the following design features:

(a) Corrosion allowance of 1 mm

(b) The tanks must withstand all wind forces as specified in SANS 4302;2002 / ISO 4302;

“Cranes - Wind Load Assessment” 1981. A basic wind speed of 50 m/s (as measured at

10m above ground level) must be used in conjunction with the above wind code to derive

the wind forces imposed on the tanks. Note the average hourly wind speeds in m/s are

given in Sub Part 5.2 .1.2.3 (Wind) of Part 5 (Site Information Storage Tank Specification).

Every reasonable protective device for the safety of operating personnel shall be incorporated. All

current safety regulations and requirements for such installations in force in Republic of South Africa

shall be complied with.

A contractor accepted by the Project Manager shall carry out exact calibration of the tanks.

1.2.4 Details of Tanks and Accessories Lots 1 to 2

4.1.1.1 General

The following table shall be used as a guide when sizing the fuel oil plant nozzles.

Limiting velocities

Diameters

NB≤50

80≤NB≤250

NB≥300

Transferring between tanks and unloading road tankers

1.0 m/s

1.0 m/s

1.0 m/s

Pump suction

0.6 m/s

1.0 m/s

1.8 m/s

In Plant

2.0 m/s

3.0 m/s

4.5 m/s

Main link

1.0 m/s

2.0 m/s

2.1 m/s

4.1.1.2 Operational philosophy of Diesel Fuel Oil tanks

Diesel Fuel tanks are required for Ankerlig Power Station and they will be arranged as shown in

P&ID’s 0.87/1 and 0.88/1 respectively included in Appendix E.

On Atlantis there will be two tanks whereby the diesel fuel oil can be received from road tanker by

either of two tanks. The normal operation is that both tanks will be nominated as the dirty receiving

tanks and will therefore not require a floating suction. Diesel fuel off loading from the road tankers to

the new tanks will be linked to the existing off loading bays in Ankerlig 2. Diesel fuel shall be

transferred from the new storage tanks to existing Tank 3 and Tank 2. If required this will allow for

one tank at a time to be taken out of service for maintenance. New storage tank selection for

offloading shall be done with remote control valve selection. Tank design shall include ports and

isolating valves for offline filtration system.


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1.2.4.1 General

Part 2.4 Schedule G contains the full details of the material specifications provided by the contractor.

The shell plate material shall also meet the code requirements including toughness, impact test and

heat treatment.

All shell vertical and horizontal joints shall be butt-welded with full penetration.

Wind girders must be of the external type (if required).

Roof plates to be additionally seal welded internally.

The Contractor is responsible for the design, manufacture, installation and commissioning of floating

suctions in the distillate fuel oil tanks including all associated pipe work and ancillaries.

1.2.4.2 Design Standards

All work shall be in accordance with the most recent edition of the relevant ASME, API, ASTM,

British Standard Specification or equivalent. The distillate tanks shall be of steel circular welded

construction and shall be fully compliant with:

American Petroleum Institute (API), API 650: Welded Steel Tanks for Oil Storage

API Recommended Practice 2350: Overfill Protection for Storage Tanks in Petroleum

Facilities

API 2000: Venting Atmospheric and Low Pressure Storage Tanks

All dimensions and quantities shall be expressed in SI units.

1.2.4.3 Tank Drainage

A draw-off sump shall be located at the centre of each tank and the tank floor shall be adequately

sloped to the sump to ensure complete drainage of water. The drainage slope shall not be less than

one in sixty.

1.2.4.4 Nozzle Details and Fittings

All nozzle flanges and blanks are to be raised faced ANSI Class 150. The Contractor shall provide

blanks and gaskets for all nozzles and fittings. All gaskets shall be of the spiral wound type. These

may be used during the hydro-test and are to be kept as spares by the Employer on completion of

the hydro-test. Additional gaskets shall be provided for those used during the hydro-test. An overflow

pipe shall be piped externally to 1m above the ground level. Precise nozzle orientations will be

agreed with the Project Manager. Confirmation of the precise orientation of the nozzles will be

provided by the Project Manager two months after contract award.

For tendering purposes a nozzle schedule has been included but tank nozzle orientation will be

different for each individual tank.

Nozzle allowable loadings shall be provided by the Contractor to the Employer within one month of

contract award.

1.2.4.5 Materials

All materials shall be new, and of a quality most suited to the proposed application.

1.2.4.6 Instrumentation

For each tank the Contractor shall provide the level gauge and temperature gauge at eye level

including isolation valves.


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All instrumentation shall be fit for use and suitable for the hazardous zone classification of the tanks.

The Contractor shall include all supports for cable trays including to roof instruments.


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Lot 1: Two (2) off 21000 m³ Distillate Fuel Tank (Welded) for Atlantis Site.

Tank requirements are as follows:

Tanks to have usable capacity of 21000m3

Water draw-off sumps with necessary pipe connections to outside shell c/w external valves

Three earthing bosses spaced at 120° to be located at low level

Asbestos gaskets are not allowed

One 750 mm external spiral stairway with intermediate landing(s) and handrail on tank and

chain barriers at top and base

One external ladder with intermediate landing(s) and safety cage on tank

Transition landing and staircase from base of spiral staircase to ground level

Gangways across tank roof to the various roof connections

One handrail around periphery of tank roof. Handrails to be fitted with toe plates

Sign at top of tank indicating safe load for personnel access

Membrane system under tank floor

Name Plate incorporating description, KKS coding, contents and code of construction

Permanent wind girders where required

Mechanical tank level indicators (Varec)

All handrails to be of angle iron design with flat bar mid and toe plates

Fill lines and main return lines to tanks to be fitted with diffusers and to conform to NFPA

30 guidelines with regards to anti-static electricity

All tank internals to be removable through local manways

Nozzles shall be provided as outlined below:

No. Flowrate

kg/s

Size NB Elevation Description

M1 - 600 1000 Shell manway c/w cover

M2 - 900 1000 Shell manway c/w cover & davit

M3 - 600 Roof Roof manway c/w cover

M4 - 600 Roof Roof manway c/w cover

N1 168 500 500 Fuel supply to storage Tank 2 and 3

N2 55 300 425 Fill line from unloading skid (with internal piping

and diffuser

N3 66 300 425 Clean oil return line with diffuser from offline

filtration

N4 150 400 16300 Main return line with vacuum breaker with

diffuser

N5 66 300 425 Feed line offline filtration system

N6 - 25 225 Access port for level transmitter

N7 - 50 1500 Access port for temperature gauge


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No. Flowrate

kg/s

Size NB Elevation Description

N8 - 50 2000 Access port for temperature transmitter

N9 - 100 150 Sump drain at low level

N10 - 250 Roof Tank breather on roof

N11 - 250 Roof Tank breather on roof

N12 - 100 Roof Dip hatch with cap and chain on roof

N13 - 100 Roof Dip hatch with cap and chain on roof

N14 - 100 Roof Access port for electronic level transmitter

N15 - 300 425 Spare fill line at ground level

N16 400 Balance Line

N17 - 300 425 Spare fill line at ground level with diffuser

N18 - 50 1500 Spare nozzle at low level

N19 - 25 Roof Access port for high-high level switch

N20 - 40 Roof Access port for local visual level indicator

N21 - 100 Roof Access port for radar level transducer

N22 - 100 Roof Access port for radar level transducer

N23 26 250 1500 Fuel transfer nozzle

N24 26 250 1500 Fuel transfer nozzle at low level with diffuser

1.2.5 Details of Tank and Accessories Lot 3

Lot 3: One (1) No. 2000 m³ fire water storage tank Atlantis Site

Tank requirements are as follows:

The firewater tank is to be of bolted Braithwaite design

Tank partitioned into two compartments each with usable volume of 1000m3

Each compartment to be fitted with all required nozzles including raw water inlet, outlet to

fire system and outlet to water treatment system

Water draw-off sump with necessary pipe connections to outside shell c/w external valves

Three earthing bosses located at low level

Asbestos gaskets are not allowed

Each compartment to have one internal ladder from base to roof manway

One external ladder per compartment with safety cage on tank. Ladders shall have

intermediate platforms where required by BS EN ISO 14122.

Gangways across tank roof to the various roof connections

Manways to have padlock facility

A handrail around the periphery of the tank roof

All handrails to be of angle iron design with flat bar mid and toe plates


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Sign at top of tank indicating safe load for personnel access

Name Plate incorporating description, KKS coding, contents and code of construction

One mechanical local visual level indicator per compartment

Nozzles shall be provided as outlined below:

No. Size NB Description

M1 600 Shell man-way on roof - Compartment 1




N1 150 Fire recirculation at high level – Compartment 1

N2 150 Fire recirculation at high level – Compartment 2

N3 300 Water supply to fire-fighting at low level – Compartment 1

N4 300 Water supply to fire-fighting at low level – Compartment 2

N5 150 Spare nozzle at high level – Compartment 1

N6 150 Spare nozzle at high level – Compartment 2

N7 250 Return line from fire-fighting at high level – Compartment 1

N8 250 Return line from fire-fighting at high level – Compartment 2

N9 150 Inlet from mains water at high level – Compartment 1

N10 150 Inlet from mains water at high level – Compartment 2

N11 150 Spare fill line at high level - Compartment 1

N12 150 Spare fill line at high level – Compartment 2

N13 100 Access port for level gauge at high level – Compartment 1

N14 100 Access port for level gauge at high level – Compartment 2

N15 100 Access port for level gauge at low level – Compartment 1

N16 100 Access port for level gauge at low level – Compartment 2

N17 100 Drain at low level – Compartment 1






N23 150 Spare at low level – Compartment 1




N27 200 Water test nozzle on roof – Compartment 1

N28 200 Water test nozzle on roof – Compartment 2


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No. Size NB Description

N29 250 Tank breather on roof – Compartment 1




N33 100 Dip hatch with cap and chain on roof – Compartment 1




N37 100 Access port for electronic level measurement – Compartment 1

N38 100 Access port for electronic level measurement – Compartment 2

N39 200 Overflow at high-high level – Compartment 1

N40 200 Overflow at high-high level – Compartment 2

N41 50 Water supply to water treatment skid (located to reserve 800m3 for fire

water) – Compartment 1

N42 50 Water supply to water treatment skid (located to reserve 800m3 for fire

water) – Compartment 2

1.2.6 Corrosion Protection

The tank, including the underside of the tank floor-plates, should be fully protected against

deterioration from corrosion. For distillate fuel and lubrication oil the interior of the tanks shall have a

protective coating system applied to the tank bases and the tank shells. For the fuel oil tanks the

painting systems applied should be chemically resistant to distillate fuel oil. Similarly the painting

system used for the lubrication oil tanks should be chemically resistant to the lubrication oil utilised.

For water storage a suitable protective coating system shall be applied to the entire interior and

exterior of the tank shell and roof. Paint shall be applied by airless spray. All handrails, stairs,

ladders, support structures and catwalks shall be hot dipped galvanised.

1.2.6.1 Exterior Paint Protection System

The paint protection system proposed for application to carbon steel parts on the external shell and

under-floor of the tank floor plates shall conform to EN ISO 12944 to C5-M or equivalent. The

Contractor shall detail the proposed painting system and standards in Schedule H (Painting

Specification) of Sub Part 2.4 (Data Schedules) of Part 2 (Tender Returnables). The colour of the

paint for the exterior shall be white as agreed by the Project Manager.

1.2.6.2 Underside of Tank Floor-plates Paint Protection System

The Underside of Tank Floor-plates shall be painted with an appropriate paint protection system in

sufficient time to allow paint to dry freely before placing in position for commencement of welding.

The Contractor should detail the proposed painting system and standards in section Schedule H

(Painting Specification) of Sub Part 2.4 (Data Schedules) of Part 2 (Tender Returnables). The

Contractor should also detail the potential lifetime of the paint protection system.


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1.2.6.3 Interior Paint Protection System

The internal of the tank shell shall be painted with an appropriate paint protection system. The tank

shall be painted once the hydro-test has been completed. The Contractor should detail the proposed

painting system and standards in section Schedule H (Painting Specification) of Sub Part 2.4 (Data

Schedules) of Part 2 (Tender Returnables).

1.2.7 Cleanliness, Preparation, Painting, Finishing and Repairs of Painted

Surfaces

1.2.7.1 Cleanliness of the System: Treatment of Internal Surfaces

Every reasonable precaution shall be taken to ensure the cleanliness of the system at pre-

manufacture stages and during manufacture, assembly, erection and commissioning of the tank.

The Contractor shall comply with the conditions stipulated in this clause over and above the normal

procedures adopted for ensuring cleanliness. The Contractor and his sub-Contractors shall comply

with all reasonable requirements of the Project Manager in maintaining the highest standards of

workmanship and cleanliness during erection.

1.2.7.2 Protection, Painting, Finishing and Packing

The tanks shall be suitably protected at all stages of construction. Subsequent to final manufacture

phase, all tank components shall be protected against deterioration due to corrosion. This

requirement covers storage at the Contractor’s works, packing for transport, transport arrangements

and storage on Site.

1.2.7.3 Surface Preparation and Conditions for Painting

All surfaces shall be dry and free of dust, salts, greases and other contaminants immediately before

coating.

The metal surface temperature as specified by the paint manufacturer shall be adhered to.

1.2.7.4 External Tank Painting and Under-floor Plates

Shot or grit blasting to ISO 8501-1:1988 SA 2.5 shall clean the surface. Detritus shall be removed

from the surface by vacuum cleaning. The blast profile achieved shall be between 50 and 100

microns. Priming paint shall be applied within four hours of surface preparation otherwise the

surfaces shall be re-prepared.

1.2.7.5 Internal Tank Painting

Shot or grit blasting to ISO 8501-1:1988 SA 3 shall clean the surface. Detritus shall be removed

from the surface by vacuum cleaning. The blast profile achieved shall be between 50 and 100

microns. Priming paint shall be applied within four hours of surface preparation otherwise the

surfaces shall be re-prepared.

1.2.7.6 Priming Coats – Shop Priming Coat

Where the Contractor wishes to use pre-primed steel plate and sections for fabricating the plant, the

shop-priming coat shall conform to the following.

A priming coat of a weldable two component low build epoxy resin based zinc phosphate paint shall

be applied to a dry film thickness (DFT) of 15 to 20 microns. (see API 650 section 5.2.1.9)


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1.2.7.7 Post Welding Surface Treatment and Priming

Immediately after completion of welding, the areas of paintwork which have been affected by the

welding process shall be shot blasted and primed to conform to Sub Part 1.2.7.6 (Priming Coats –

Shop Priming Coat) first priming coat.

1.2.7.8 Repair of Damaged Paint-work

All paintwork, which may be damaged during transport, handling, storage or erection, shall be

repaired on Site as follows:

Priming Coat Damaged - External and Under-floor Plates

Where the priming coat has been damaged, the damaged area shall be power wire brushed to clean

metal equivalent to ISO 8501-1:1988 - St 3. This shall be followed by vacuum cleaning to remove

detritus and the full paint shall be re-applied to the affected area to a total DFT of 350 microns,

minimum.

Priming Coat Damaged - Internal Tank Plates

Where the priming coat has been damaged, the damaged area shall be shot or grit blasted to clean

metal equivalent to ISO 8501-1:1988 – Sa 2.5. This shall be followed by vacuum cleaning to remove

detritus and the full paint shall be re-applied to the affected area to a total DFT of 350 microns,

minimum.

Potential Life of Restored Paintwork

All remedial action shall restore the damaged coating to the same potential life as that of the

undamaged areas.

1.2.7.9 Control of Paint Thickness

For consistent and economical application of paint, the paint film thickness shall be controlled during

application by monitoring the Wet Film Thickness (WFT). A relationship shall be established

between WFT and DFT beforehand by preparing and painting a suitable test plate, before

preparation of metal surfaces for painting occurs.

Dry Film Thickness

Method of determining the final DFT shall be to take readings over any square metre of the painted

area, the average of these readings shall equal or exceed the nominal DFT and in no case shall any

reading be less than 75% of nominal DFT. The same method shall be applied to determining WFT.

1.2.7.10 Areas for Special Attention

Special attention shall be given to painting of:

Mating surfaces of connections

Contact surfaces with concrete

Interior Base of Tank

Welds and areas adjacent to welds

Strip coats should be applied if deemed necessary


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1.2.7.11 Compatibility of Paints

All paints shall be by the same manufacturer and shall be compatible with one another.

1.2.8 Pipework

All pipe-work for fuel storage shall be API 5L grade B schedule 40.

All pipe-work for water storage shall be to galvanised carbon steel (ASTM A106 grade B or API 5L

B).

1.2.9 Tank Labelling

The Contractor shall provide labelling on the tank stating the tank number and the type of (liquid) fuel

it contains. This should be clearly seen from the outside of the bund.

1.2.10 Civil Requirements

1.2.10.1 Materials for Civil Works

The Contractor shall supply all embedded anchor bolts, jacking posts, sleeves, anchors and other

miscellaneous embedded parts necessary for the installation of the tanks and required to be

incorporated in the civil works, including, if necessary, setting templates required for anchor bolt

placement. A civil contractor will incorporate all such items into the structures under a separate

contract. Materials shall be supplied and proper and sufficient drawings and templates shall be

provided in sufficient time to ensure the items are incorporated in the civil works.

1.2.10.2 Information for Civil Works

Information required for the timely planning, design and construction of the civil works shall be

provided by the Contractor as required. The Contractor provides all the necessary information in the

detail required and at the appropriate time. The Contractor specifies any specific requirements for

tank foundations taking into consideration local conditions.

Information shall be provided at three levels of detail namely outline, basic and definitive.

Outline information shall include the main dimensions and arrangement planning of structures

together with preliminary plant loads.

Basic information shall be at such level of detail as to allow the execution of calculations to within an

accuracy of +10% and the preparation of draft drawings. Basic information shall be provided within 1

week of contract award.

Definitive information shall provide final definitive loading information and allow the preparation of

detailed execution and construction drawings for the civil works. Definitive information shall be

provided within 4 weeks of contract award.

The information to be provided shall include the following:

Design Calculations

Arrangement drawing indicating detailed tank geometry

Loadings imposed by tank and equipment

Criteria for settlement of tank foundations


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Details of all plinths, openings, box-outs holding down arrangements, grouting etc.,

required for tank

1.2.11 Final Information to be Supplied before Contract Completion

A technical file for the Storage Tanks shall be submitted prior to the Completion Date.

A Table of Contents for the technical file shall be submitted to the Project Manager for comment and

review prior to the compilation of the technical file.

Four hard copies of all documentation shall be submitted before the Contract is deemed to be

complete. In addition to the hard copies a soft copy shall also be submitted, with all files in their

native application.

The Contractor shall supply complete descriptive details and as built drawings of the tanks, giving

full particulars of the materials used.

The Contractor shall submit detailed loading values of the tank giving the maximum loads. Any point

loads shall be identified and their location detailed on a drawing.

The Contractor shall submit a detailed record of material certificates, the plate preparation, welding

and NDE records, and hydro-test results.


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1.3. APPENDICES


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1.3.1 APPENDIX A – CODES AND STANDARDS

API 2000, 5th Edition, Apr. 1998 Venting Atmospheric and Low-Pressure Storage Tanks

API Recommended Practice 2350, 3rd

Edition, Jan. 2005

Overfill Protection for Storage Tanks in Petroleum Facilities

API Standard 650 10th Edition, Nov. 1998 Welded Steel Tanks for Oil Storage

BS2654:1989 British Standard Specification for Manufacture of vertical

steel welded non-refrigerated storage tanks with butt-

welded shells for the petroleum industry

EN14015: 2004 Specification for the design and manufacture of site built,

vertical, cylindrical, flat-bottomed, above ground, welded,

steel tanks for the storage of liquids at ambient

temperature and above

BS EN ISO 14122 (Part 1 to 4 inclusive) Safety of machinery – Permanent means of access to

machinery

ESKAMAAD1 Rev 2 Storage and Handling of Flammable and Combustible

Liquids

GGG 0450 Guideline to Acceptance of Contractors Drawings

GGR 0992 Eskom Plant Safety Regulations

GGS 0445 Drawing numbering system

GGSS 0317 Specification for Storage Tanks

KSA-106 Requirements For Protective Coatings For Use At Koeberg

Nuclear Power Station

OPS 0002 Eskom Documentation Standard

SABS 1109 ISO pipe threads for pipes and fittings where pressure –

tight joints are made on the threads.

SABS 1123 Steel pipe flanges

SABS 719 Electric welded low carbon steel pipes for aqueous fluids

(ordinary Duties)

SABS 763 Hot-dip (galvanized) zinc coatings

SABS 974-1 Rubber joint rings (non-cellular) for use in water, sewer and

drainage systems

SANS 10089-1:2003 Part 1 Storage and distribution of petroleum products in above-

ground bulk installations

SANS 10108 The classification of hazardous locations and selection of

electric apparatus for use in such locations

SANS 10140-3 Identification Colour Markings

SANS 1091 National colours for paint

SANS 9000 to 9004 Quality Management systems and standards

1.3.2


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1.3.3 APPENDIX B – ABBREVIATION LIST

BOP Balance of Plant

C&I Control & Instrumentation

DCIS Distributed Control and Information System

EN European Norm

ESV Emergency Stop Valve

FAT Factory Acceptance Test

GRP Glass- Reinforced Polyester

GT Gas Turbine

HMI Human Machine Interface

HV High Voltage

LCS Local Control Push Button Station

MCB Miniature Circuit Breaker’s

MCC Motor Control Centre

NB Nominal Bore

NEC New Engineering Contract

NDT Non-Destructive Testing

NERSA National Energy Regulator of South Africa

NFPA National Fire Protection Association

OCGT Open Cycle Gas Turbine

OEM Original Equipment Manufacturer

OHSA Occupational Health and Safety Authority

O&M Operation and maintenance

PCC Power Control Centre

PLC Programme Logic Control

PIP Project Implementation Plan

PPE Personal Protective Equipment

PSQP Project Specific Quality Plan

P&ID Piping and Instrumentation Diagram

QAM Quality Assurance Manual

SANS South African National Standard

SAT Site Acceptance Test

SHEQ Safety, Health, Environment & Quality

SI International System

SQAP Site Quality Assurance Programme

SWL Safe Working Loads


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WPS Welding Procedure Specification

WPAR Weld Procedure Approval Records

WQAP Works (Manufacturer’s Facility) Quality Assurance Programme

WQR Welder Qualification Records


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1.3.4 APPENDIX C – SAFETY, HEALTH AND ENVIRONMENTAL

Appendix C - Section 1

Ankerlig Safety, Health & Environmental Specification


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Appendix C - Section 2

Environmental Report


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1.3.5 APPENDIX D - CORROSION PROTECTION


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1.3.6 APPENDIX E - DRAWINGS

The following Drawings are included in the enquiry:

Atlantis Ankerlig 2 Site

0.88/1 Station Layout

0.88/4 P&ID Demineralised Water System

0.88/8 P&ID Fire Water System

0.88/28 Fire water storage tank

RSA805-UC07-UZ-110001 Siemens Layout Showing Terminal Points

ankerlig additional storage tanks

Documents

blast profile achieved

plate incorporating description

ankerlig power station

therewith including payments

flat bar mid

diesel fuel oil

cable trays including

angle iron design