nec3 engineering & construction contract ec… · eskom holdings soc ltd contract no. _____...

ESKOM HOLDINGS SOC Ltd CONTRACT NO. _________ DESIGN AND CONSTRUCT ASH HOPPER AERATION SYSTEM AT CAMDEN POWER STATION FOR THE CAMDEN ASH HANDLING PLANT UPGRADE PROJECT

PART C2: PRICING DATA PAGE 1 C2 ECC3/A COVER

NEC3 Engineering & Construction Contract

Between

ESKOM HOLDINGS SOC Ltd (Reg. No. 2002/015527/30)

and

[Insert at award stage] (Reg. No. ___________ )

for

the design and construction Ash Hopper Aeration System at Camden Power Station for the Camden Ash Handling Plant Upgrade Project

Contents:

No of pages

Part C1 Agreements & Contract Data [●]

Part C2 Pricing Data [●]

Part C3 Scope of Work [●]

Part C4 Site Information [●]

CONTRACT No. [Insert at award stage]



C1.1 Form of Offer & Acceptance

Offer The Employer, identified in the Acceptance signature block, has solicited offers to enter into a contract for the procurement of: The tenderer, identified in the Offer signature block, has examined the documents listed in the Tender Data and addenda thereto and by submitting this Offer has accepted the Conditions of Tender. By the representative of the tenderer, deemed to be duly authorised, signing this part of this Form of Offer and Acceptance the tenderer offers to perform all of the obligations and liabilities of the Contractor under the contract including compliance with all its terms and conditions according to their true intent and meaning for an amount to be determined in accordance with the conditions of contract identified in the Contract Data.

Options A The offered total of the Prices exclusive of VAT is R

Sub total R

Value Added Tax @ 15% is R

The offered total of the amount due inclusive of VAT is R

(in words).

This Offer may be accepted by the Employer by signing the Acceptance part of this Form of Offer and Acceptance and returning one copy of this document including the Schedule of Deviations (if any) to the tenderer before the end of the period of validity stated in the Tender Data, or other period as agreed, whereupon the tenderer becomes the party named as the Contractor in the conditions of contract identified in the Contract Data. Signature(s)

Name(s)

Capacity

For the tenderer:

Name & signature of witness

Date

Tenderer’s CIDB registration number (if applicable)



Part C1: Agreements & Contract Data

Contents:

No of pages

C1.1 Form of Offer and Acceptance

[●]

C1.2a Contract Data provided by the Employer [●]

C1.2b Contract Data provided by the Contractor [●]

C1.3 Proforma Guarantees [●]



Acceptance By signing this part of this Form of Offer and Acceptance, the Employer identified below accepts the tenderer’s Offer. In consideration thereof, the Employer shall pay the Contractor the amount due in accordance with the conditions of contract identified in the Contract Data. Acceptance of the tenderer’s Offer shall form an agreement between the Employer and the tenderer upon the terms and conditions contained in this agreement and in the contract that is the subject of this agreement. The terms of the contract, are contained in:

Part C1 Agreements and Contract Data, (which includes this Form of Offer and Acceptance) Part C2 Pricing Data Part C3 Scope of Work: Works Information Part C4 Site Information

and drawings and documents (or parts thereof), which may be incorporated by reference into the above listed Parts. Deviations from and amendments to the documents listed in the Tender Data and any addenda thereto listed in the Returnable Schedules as well as any changes to the terms of the Offer agreed by the tenderer and the Employer during this process of offer and acceptance, are contained in the Schedule of Deviations attached to and forming part of this Form of Offer and Acceptance. No amendments to or deviations from said documents are valid unless contained in this Schedule. The tenderer shall within two weeks of receiving a completed copy of this agreement, including the Schedule of Deviations (if any), contact the Employer’s agent (whose details are given in the Contract Data) to arrange the delivery of any securities, bonds, guarantees, proof of insurance and any other documentation to be provided in terms of the conditions of contract identified in the Contract Data at, or just after, the date this agreement comes into effect. Failure to fulfil any of these obligations in accordance with those terms shall constitute a repudiation of this agreement. Notwithstanding anything contained herein, this agreement comes into effect on the date when the tenderer receives one fully completed original copy signed between them of this document, including the Schedule of Deviations (if any). Unless the tenderer (now Contractor) within five working days of the date of such receipt notifies the Employer in writing of any reason why he cannot accept the contents of this agreement, this agreement shall constitute a binding contract between the Parties. Signature(s)

Name(s)

Capacity

for the Employer

Eskom Holdings SOC Ltd, Megawatt Park, Maxwell Drive, Sandton, Johannesburg, 2199


Date

.



Schedule of Deviations to be completed by the Employer prior to contract award Note:

1. This part of the Offer & Acceptance would not be required if the contract has been developed by negotiation between the Parties and is not the result of a process of competitive tendering.

2. The extent of deviations from the tender documents issued by the Employer prior to the tender closing date is limited to those permitted in terms of the Conditions of Tender.

3. A tenderer’s covering letter must not be included in the final contract document. Should any matter in such letter, which constitutes a deviation as aforesaid be the subject of agreement reached during the process of Offer and Acceptance, the outcome of such agreement shall be recorded here and the final draft of the contract documents shall be revised to incorporate the effect of it.

No. Subject Details

1

2

3

4

5

By the duly authorised representatives signing this Schedule of Deviations below, the Employer and the tenderer agree to and accept this Schedule of Deviations as the only deviations from and amendments to the documents listed in the Tender Data and any addenda thereto listed in the Tender Schedules, as well as any confirmation, clarification or changes to the terms of the Offer agreed by the tenderer and the Employer during this process of Offer and Acceptance. It is expressly agreed that no other matter whether in writing, oral communication or implied during the period between the issue of the tender documents and the receipt by the tenderer of a completed signed copy of this Form shall have any meaning or effect in the contract between the parties arising from this Agreement. For the tenderer:

For the Employer

Signature

Name

Capacity

On behalf of

Eskom Holdings SOC Ltd, Megawatt Park, Maxwell Drive, Sandton, Johannesburg, 2199


Date



C1.2 ECC3 Contract Data

Part one - Data provided by the Employer

Clause Statement Data

1 General

The conditions of contract are the core clauses and the clauses for main Option

A: Priced contract with activity schedule

dispute resolution Option W1: Dispute resolution procedure

and secondary Options

X2: Changes in the law

X7: Delay damages X13: Performance Bond

X16: Retention

X18: Limitation of liability

Z: Additional conditions of contract Z1-Z12

of the NEC3 Engineering and Construction Contract, April 2013 (ECC3)

10.1 The Employer is: Eskom Holdings SOC Ltd (reg no: 2002/015527/30), a state owned company incorporated in terms of the company laws of the Republic of South Africa

Address Registered office at Megawatt Park, Maxwell Drive, Sandton, Johannesburg

10.1 The Project Manager is: To be confirmed at Contract Placement

Address Camden Power Station N2 Piet Retief Road Private Bag X1002 NUCAM 2533

Tel To be confirmed at Contract Placement

e-mail To be confirmed at Contract Placement

10.1 The Supervisor is: To be confirmed at Contract Placement

Address Camden Power Station N2 Piet Retief Road



Private Bag X1002 NUCAM 2533

Tel No. To be confirmed at Contract Placement

e-mail To be confirmed at Contract Placement

11.2(13) The works are Design and construct ash hopper aeration system at Camden Power Station for the Camden Ash Handling Plant Project

11.2(14) The following matters will be included in the Risk Register

Access to existing areas

Labour/community unrest

Extreme weather

Unavailability of generation plant

Non-compliance to approved environmental Management Programme

Contractors poor performance during project

Access from mechanical Contractor

Working at heights

Electrocution

Power supply interruptions or failure

Contractor poor performance during project execution.

Uncertain integrated schedule.

Inability to integrate the new plant with the upgraded existing plant.

Complex interfacing of the new and old control and instrumentation systems.

The ash handling plant upgrade not completed before the new ash dam, leading to delayed ashing to the new facility.

11.2(15) The boundaries of the site are as per drawing no. 15032/73-00-01 and areas indicated in the Site Information

11.2(16) The Site Information is in Part 4: Site Information

11.2(19) The Works Information is in Part 3: Scope of Work and all documents and drawings to which it makes reference.

12.2 The law of the contract is the law of the Republic of South Africa

13.1 The language of this contract is English

13.3 The period for reply is 7 working days

2

The Contractor's main

Data required by this section of the core



responsibilities clauses is provided by the Contractor in Part 2 and terms in italics used in this section are identified elsewhere in this Contract Data.

3 Time

11.2(3) The completion date for the whole of the works is

11.2(9) The key dates and the conditions to be met are:

Condition to be met key date

1 All works to be completed

30 October 2020

30.1 The access dates are: All of the Site Date

08 April 2020

31.1 The Contractor is to submit a first programme for acceptance within

One week of the Contract Date.

31.2 The starting date is 21 April 2020

32.2 The Contractor submits revised programmes at intervals no longer than

1 week

4 Testing and Defects

42.2 The defects date is 52 weeks after Completion of the whole of the works.

43.2 The defect correction period is 5 days

5 Payment

50.1 The assessment interval is The assessment interval is one (1) month. This will be done on the 25th of each month.

51.1 The currency of this contract is the South African Rand.

51.2 The period within which payments are made is

Monthly on the last working day of the month following the assessment

51.4 The interest rate is the publicly quoted prime rate of interest (calculated on a 365 day year) charged from time to time by the Standard Bank of South Africa Limited (as certified, in the event of any dispute, by any manager of such bank, whose appointment it shall not be necessary to prove) for amounts due in Rands and

6 Compensation events



60.1(13)

The place where weather is to be recorded is: The weather measurements to be recorded for each calendar month are, Assumed values for the ten year return weather data for each weather measurement for each calendar month are:

Camden Power station As stated in Annexure A to this Contract Data provided by the Employer.

the cumulative rainfall (mm) the number of days with rainfall more than 10 mm the number of days with minimum air temperature less than 0 degrees Celsius the number of days with snow lying at 08:00 hours South African Time and these measurements

7 Title

8 Risks and insurance

80.1 These are additional Employer’s risks None

84.1

The Employer provides these insurances from the Insurance Table

as stated in Annexure C Insurance Schedule (See Annexure B for basic guidance

84.1

The Employer provides these additional insurances

As per the Employers Assets All Risks Insurance Policy

84.1 The Contractor provides these additional insurances:

Whatever the Contractor deems necessary in addition to the insurance provided by the Employer plus the amount of the deductibles per claim and without limit to the number of claims that may arise during the period of insurance.

84.2 The insurance against loss of or damage to the works, Plant and Materials is to include cover for Plant and Materials provided by the Employer for an amount of

the value of the Plant and Materials

84.2

The minimum limit of indemnity for insurance in respect of loss of or damage to property (except the works, Plant, Materials and Equipment) and liability for bodily injury to or death of a person (not an employee of the Contractor) caused by activity in connection with this contract for any one event is

Whatever the Contractor deems necessary in addition to that provided by the Employer.

84.2 The minimum limit of indemnity for insurance in respect of death of or bodily injury to employees of the Contractor arising out of and in the course of their employment in connection with this contract for any one event is

As prescribed by the Compensation for Occupational Injuries and Diseases Act No. 130 of 1993 and the Contractor’s common law liability for people falling outside the scope of the Act with a limit of Indemnity of not less than R500 000 (Five hundred thousand Rands) or as per the laws of the country in which the Contractor`s employees are domiciled.



9 Termination

10 Data for main Option clause

11 Data for Option W1

W1.1 The Adjudicator is The person selected from the ICE-SA Division (or its successor body) of the South African Institution of Civil Engineering Panel of Adjudicators by the Party intending to refer a dispute to him. (see www.ice-sa.org.za).

W1.2(3) The Adjudicator nominating body is: the Chairman of ICE-SA a joint Division of the South African Institution of Civil Engineering and the London Institution of Civil Engineers. (See www.ice-sa.org.za ) or its successor body.

W1.4(2) The tribunal is: Arbitration.

W1.4(5) The arbitration procedure is the latest edition of Rules for the Conduct of Arbitrations published by The Association of Arbitrators (Southern Africa) or its successor body.

The place where arbitration is to be held is Johannesburg South Africa

The person or organisation who will choose an arbitrator - if the Parties cannot agree a choice or - if the arbitration procedure does not

state who selects an arbitrator, is

the Chairman for the time being or his nominee of the Association of Arbitrators (Southern Africa) or its successor body.

12 Data for secondary Option clauses

X2 Changes in the law

X7 Delay damages (but not if Option X5 is also used)

X7.1 Delay damages for Completion of the whole of the works are

R10 000.00 per day up to 10 % of contract value. The Employer reserves the right to terminate one 10%of delay damages threshold has been reached.

X13 X13.1

Performance bond The amount of the performance bond is

5 % of the Contract Amount at Contract Date.

X15 Limitation of the Contractor’s liability for his design to reasonable skill & care

http://www.ice-sa.org.za/

http://www.ice-sa.org.za/



X16 Retention

X16.1 The retention free amount is 5%

The retention percentage is Five percent of the total of the Prices.

X18 Limitation of liability

X18.1 The Contractor’s liability to the Employer for indirect or consequential loss is limited to:

R0.0 (zero Rand)

X18.2 For any one event, the Contractor’s liability to the Employer for loss of or damage to the Employer’s property is limited to:

the amount of the deductibles relevant to the event described in the insurance policy format selected in the data for clause 84.1 above, which policy is available on

X18.3 The Contractor’s liability for Defects due to his design which are not listed on the Defects Certificate is limited to

the total of the prices at the Contract Date

X18.4 The Contractor’s total liability to the Employer for all matters arising under or in connection with this contract, other than excluded matters, is limited to:

The Contractor’s total liability for all the matters arising under or in connection with this contract , other than excluded matters are to: The total of the Prices other than for the additional excluded matters. The Contractor’s total liability for the additional excluded matters is not limited. The additional excluded matters are amounts for which the Contractor is liable under this contract for

loss of or damage to property (other than the works, Plant and Material).

Infringement of an intellectual property right.

Defects due to his design which arise before the Defects Certificate is issued,

X18.5 The end of liability date is (i) 7 years after the defects date for latent Defects and (ii) the date on which the liability in question prescribes in accordance with the Prescription Act No. 68 of 1969 (as amended or in terms of any replacement legislation) for any other matter. A latent Defect is a Defect which would not have been discovered on reasonable inspection by the Employer or the Supervisor before the defects date, without requiring any inspection not ordinarily carried out by the Employer or the Supervisor during that period.



If the Employer or the Supervisor do undertake any inspection over and above the reasonable inspection, this does not place a greater responsibility on the Employer or the Supervisor to have discovered the Defect.

Z1 Cession delegation and assignment

Z1.1 The Contractor does not cede, delegate or assign any of its rights or obligations to any person without the written consent of the Employer.

Z1.2 Notwithstanding the above, the Employer may on written notice to the Contractor cede and delegate its rights and obligations under this contract to any of its subsidiaries or any of its present divisions or operations which may be converted into separate legal entities as a result of the restructuring of the Electricity Supply Industry.

Z2 Joint ventures

Z2.1 If the Contractor constitutes a joint venture, consortium or other unincorporated grouping of two or more persons or organisations then these persons or organisations are deemed to be jointly and severally liable to the Employer for the performance of this contract.

Z2.2 Unless already notified to the Employer, the persons or organisations notify the Project Manager within two weeks of the Contract Date of the key person who has the authority to bind the Contractor on their behalf.

Z2.3 The Contractor does not alter the composition of the joint venture, consortium or other unincorporated grouping of two or more persons without the consent of the Employer having been given to the Contractor in writing.

Z3 Change of Broad Based Black Economic Empowerment (B-BBEE) status

Z3.1 Where a change in the Contractor’s legal status, ownership or any other change to his business composition or business dealings results in a change to the Contractor’s B-BBEE status, the Contractor notifies the Employer within seven days of the change.

Z3.2 The Contractor is required to submit an updated verification certificate and necessary supporting documentation confirming the change in his B-BBEE status to the Project Manager within thirty days of the notification or as otherwise instructed by the Project Manager.

Z3.3 Where, as a result, the Contractor’s B-BBEE status has decreased since the Contract Date the Employer may either re-negotiate this contract or alternatively, terminate the Contractor’s obligation to Provide the Works.

Z3.4 Failure by the Contractor to notify the Employer of a change in its B-BBEE status may constitute a reason for termination. If the Employer terminates in terms of this clause, the procedures on termination are P1, P2 and P3 as stated in clause 92, and the amount due is A1 and A3 as stated in clause 93.

Z4 Confidentiality

Z4.1 The Contractor does not disclose or make any information arising from or in connection with this contract available to Others. This undertaking does not, however, apply to information which at the time of disclosure or thereafter, without default on the part of the Contractor, enters the public domain or to information which was already in the possession of the Contractor at the time of disclosure (evidenced by written records in existence at that time). Should the



Contractor disclose information to Others in terms of clause 25.1, the Contractor ensures that the provisions of this clause are complied with by the recipient.

Z4.2 If the Contractor is uncertain about whether any such information is confidential, it is to be regarded as such until notified otherwise by the Project Manager.

Z4.3 In the event that the Contractor is, at any time, required by law to disclose any such information which is required to be kept confidential, the Contractor, to the extent permitted by law prior to disclosure, notifies the Employer so that an appropriate protection order and/or any other action can be taken if possible, prior to any disclosure. In the event that such protective order is not, or cannot, be obtained, then the Contractor may disclose that portion of the information which it is required to be disclosed by law and uses reasonable efforts to obtain assurances that confidential treatment will be afforded to the information so disclosed.

Z4.4 The taking of images (whether photographs, video footage or otherwise) of the works or any portion thereof, in the course of Providing the Works and after Completion, requires the prior written consent of the Project Manager. All rights in and to all such images vests exclusively in the Employer.

Z4.5 The Contractor ensures that all his Sub-Contractors abide by the undertakings in this clause.

Z5 Waiver and estoppel: Add to core clause 12.3:

Z5.1 Any extension, concession, waiver or relaxation of any action stated in this contract by the Parties, the Project Manager, the Supervisor, or the Adjudicator does not constitute a waiver of rights, and does not give rise to an estoppel unless the Parties agree otherwise and confirm such agreement in writing.

Z6 Health, safety and the environment: Add to core clause 27.4

Z6.1 The Contractor undertakes to take all reasonable precautions to maintain the health and safety of persons in and about the execution of the works. Without limitation the Contractor:

accepts that the Employer may appoint him as the “Principal Contractor” (as defined and provided for under the Construction Regulations 2014 (promulgated under the Occupational Health & Safety Act 85 of 1993) (“the Construction Regulations”) for the Site;

warrants that the total of the Prices as at the Contract Date includes a sufficient amount for proper compliance with the Construction Regulations, all applicable health & safety laws and regulations and the health and safety rules, guidelines and procedures provided for in this contract and generally for the proper maintenance of health & safety in and about the execution of works; and

undertakes, in and about the execution of the works, to comply with the Construction Regulations and with all applicable health & safety laws and regulations and rules, guidelines and procedures otherwise provided for under this contract and ensures that his Sub-Contractors, employees and others under the Contractor’s direction and control, likewise observe and comply with the foregoing.

Z6.2 The Contractor, in and about the execution of the works, complies with all applicable environmental laws and regulations and rules, guidelines and procedures otherwise provided for under this contract and ensures that his Sub-Contractors, employees and others under the Contractor’s direction and control, likewise observe and comply with the foregoing.

Z7 Provision of a Tax Invoice and interest. Add to core clause 51

Z7.1 Within one week of receiving a payment certificate from the Project Manager in terms of core clause 51.1, the Contractor provides the Employer with a tax invoice in accordance with the Employer’s procedures stated in the Works Information, showing the amount due for payment



equal to that stated in the payment certificate.

Z7.2 If the Contractor does not provide a tax invoice in the form and by the time required by this contract, the time by when the Employer is to make a payment is extended by a period equal in time to the delayed submission of the correct tax invoice. Interest due by the Employer in terms of core clause 51.2 is then calculated from the delayed date by when payment is to be made.

Z7.3 The Contractor (if registered in South Africa in terms of the companies Act) is required to comply with the requirements of the Value Added Tax Act, no 89 of 1991 (as amended) and to include the Employer’s VAT number 4740101508 on each invoice he submits for payment.

Z8 Notifying compensation events

Z8.1 Delete from the last sentence in core clause 61.3, “unless the Project Manager should have notified the event to the Contractor but did not”.

Z9 Employer’s limitation of liability

Z9.1 The Employer’s liability to the Contractor for the Contractor’s indirect or consequential loss is limited to R0.00 (zero Rand)

Z9.2 The Contractor’s entitlement under the indemnity in 83.1 is provided for in 60.1(14) and the Employer’s liability under the indemnity is limited.

Z10 Termination: Add to core clause 91.1, at the second main bullet point, fourth sub-bullet point, after the words "against it":

Z10.1 or had a business rescue order granted against it.

Z11 Addition to secondary Option X7 Delay damages (if applicable in this contract)

Z11.1 If the amount due for the Contractor’s payment of delay damages reaches the limits stated in this Contract Data for Option X7 or Options X5 and X7 used together, the Employer may terminate the Contractor’s obligation to Provide the Works using the same procedures and payment on termination as those applied for reasons R1 to R15 or R18 stated in the Termination Table.

Z12 Ethics

For the purposes of this Z-clause, the following definitions apply: Affected Party means, as the context requires, any party, irrespective of whether it is the Contractor

or a third party, such party’s employees, agents, or SubContractors or SubContractor’s employees, or any one or more of all of these parties’ relatives or friends,

Coercive Action means to harm or threaten to harm, directly or indirectly, an Affected Party or the

property of an Affected Party, or to otherwise influence or attempt to influence an Affected Party to act unlawfully or illegally,

Collusive Action means where two or more parties co-operate to achieve an unlawful or illegal

purpose, including to influence an Affected Party to act unlawfully or illegally,



Committing Party means, as the context requires, the Contractor, or any member thereof in the case of a joint venture, or its employees, agents, or SubContractors or the SubContractor’s employees,

Corrupt Action means the offering, giving, taking, or soliciting, directly or indirectly, of a good or

service to unlawfully or illegally influence the actions of an Affected Party, Fraudulent Action means any unlawfully or illegally intentional act or omission that misleads, or

attempts to mislead, an Affected Party, in order to obtain a financial or other benefit or to avoid an obligation or incurring an obligation,

Obstructive Action means a Committing Party unlawfully or illegally destroying, falsifying, altering or

concealing information or making false statements to materially impede an investigation into allegations of Prohibited Action and

Prohibited Action means any one or more of a Coercive Action, Collusive Action Corrupt Action,

Fraudulent Action or Obstructive Action. Z 12.1 A Committing Party may not take any Prohibited Action during the course of the procurement of this

contract or in execution thereof. Z 12.2 The Employer may terminate the Contractor’s obligation to Provide the Works if a Committing Party

has taken such Prohibited Action and the Contractor did not take timely and appropriate action to prevent or remedy the situation, without limiting any other rights or remedies the Employer has. It is not required that the Committing Party had to have been found guilty, in court or in any other similar process, of such Prohibited Action before the Employer can terminate the Contractor’s obligation to Provide the Works for this reason.

Z 12.3 If the Employer terminates the Contractor’s obligation to Provide the Works for this reason, the

procedures and amounts due on termination are respectively P1, P2 and P3, and A1 and A3. Z 12.4 A Committing Party co-operates fully with any investigation pursuant to alleged Prohibited Action.

Where the Employer does not have a contractual bond with the Committing Party, the Contractor ensures that the Committing Party co-operates fully with an investigation.



Annexure B: Insurance provided by the Employer These notes are provided as guidance to tendering Contractors and the Contractor about the insurance provided by the Employer. we 1. Tendering Contractors should note that cover provided by the Employer is only per the insurance

policies provided and may not be the cover required by the tendering Contractor or as intended by each of the listed insurances in the left hand column of the Insurance Table in clause 84.2. In terms of clause 84.1 “the Contractor provides the insurances stated in the Insurance Table except any insurance which the Employer is to provide”. Hence the Contractor provides insurance which the Employer does not provide and in cases where the Employer does provide insurance the Contractor insures for the difference between what the Insurance Table requires and what the Employer provides.

2. If Marine Insurance is required the Contractor needs to obtain a copy of the latest edition of Eskom’s

Shipment Policies and Procedures.

3. The Contractor should generally give further consideration to providing for these additional insurance concepts: for Amounts and Periods of Insurance the Contractor deems fit and necessary.

a) Professional Indemnity: The Insurance provided shall indemnify the Contractor (and/or his professional Consultant) for those sums which the Contractor or his Consultant shall become legally liable to pay as Damages arising from any claim first made against the Contractor/Consultant and reported to their Insurers during the Period of Insurance, directly arising out of any negligent act, error or omission committed or alleged to have been committed by the Contractor/Consultant in the conduct of professional services (example: design) in connection with the Contract. 4. [Also refer website’s Professional Services Contract Guidance Notes].

b) Products Liability: A special General Liability extension for liability arising out of the

Manufacturer’s/Supplier’s/Original Equipment Manufacturer’s defective: i. production and manufacturing process (workmanship or material), or ii. product design, or iii. warnings, instructions, usage and maintenance manuals and specifications.

c) Products Guarantee: For the cost of replacing, reworking or recovering products that have

failed to perform their intended function due to faulty design, manufacture, installation, after handover to the Employer.

d) Goods in Trust and under Manufacture or Storage at Manufacturer’s Premises: Where the Contract involves manufacture, and/or fabrication of Plant and Materials, components or other goods to be incorporated into the works, at premises other than the site, the Contractor shall satisfy the Employer that such Plant and Materials, components or other goods for incorporation in the works are adequately insured during manufacture and/or fabrication. Should the Employer have an insurable interest in such items during manufacture or fabrication, such interest shall be noted by endorsement to the Contractor's relevant policies of insurance as well as those of any Sub-Contractor.

5. Contract Works SASRIA insurance is subject to the terms exceptions and conditions of the SASRIA

coupon policy. Cover and Indemnity is therefore within the scope and to the extent provided by the SASRIA coupon policy.



C1.2 ECC3 Contract Data Part two - Data provided by the Contractor Notes to a tendering Contractor: Completion of the data in full, according to Options chosen, is essential to create a complete contract.

Clause Statement Data

10.1 The Contractor is (Name):

Address

Tel No.

Fax No.

11.2(8) The direct fee percentage is %

The subcontracted fee percentage is %

11.2(18) The working areas are the Site and

24.1 The Contractor's key persons are:

1 Name:

Job:

Responsibilities:

Qualifications:

Experience:

2 Name:

Job

Responsibilities:

Qualifications:

Experience:

CV's (and further key persons data including CVs) are appended to Tender Schedule entitled .

11.2(3) The completion date for the whole of the works is

11.2(14) The following matters will be included in the Risk Register

11.2(19) The Works Information for the Contractor’s design is in:

31.1 The programme identified in the Contract Data is

A Priced contract with activity schedule

11.2(20) The activity schedule is in



11.2(30) The tendered total of the Prices is (in figures) (in words), excluding VAT



C1.3 Forms of Securities Pro formas for Bonds & Guarantees For use with the NEC3 Engineering & Construction Contract (June 2005) The conditions of contract stated in the Contract Data Part 1 include the following Secondary Options: Option X13: Performance Bond Each of these secondary Options requires a bond or guarantee “in the form set out in the Works Information”. Pro forma documents for these bonds and guarantees are provided here for convenience but are to be treated as part of the Works Information. The organisation providing the bond / guarantee does so by copying the pro forma document onto his letterhead without any change to the text or format and completing the required details. The completed document is then given to the Employer within the time stated in the contract.



Pro forma Performance Bond – Demand Guarantee (for use with Option X13) (to be reproduced exactly as shown below on the letterhead of the Contractor’s Parent Company)

Eskom Holdings SOC Ltd Megawatt Park Maxwell Drive Sandton Johannesburg Date:

Dear Sirs Reference No. [●] [Drafting Note: Bank reference number to be inserted] Performance Bond – Demand Guarantee: [Drafting Note: Name of Contractor to be inserted] Project [ ] Contract Reference: …… [Drafting Note: Contractor contract reference number to be inserted] 1. In this Guarantee the following words and expressions shall have the following meanings:- 1.1 “Bank” - means [●], [●] Branch, (Registration No. [●]); [Drafting Note: Name of Bank to be

inserted]

1.2 “Bank’s Address” - means [●]; [Drafting Note: Bank’s physical address to be inserted] 1.3 “Contract” – means the written agreement relating to the Project, entered into between

Eskom and the Contractor, on or about the [●] day of [●] 200[●] (Contract Reference No. [.]as amended, varied, restated, novated or substituted from time to time; [Drafting Note: Signature Date and Contract reference number to be inserted]

1.4 “Contractor” – means [●] a company registered in accordance with the laws of [●] under Registration Number [●]. [Drafting Note: Name and details of Contractor to be inserted]

1.5 “Eskom” - means Eskom Holdings SOC Ltd, a company registered in accordance with the laws of the Republic of South Africa under Registration Number 2002/015527/30].

1.6 “Expiry Date” - means the date on which the Defects Certificate is issued in terms of the Contract.

1.7 “Guaranteed Sum” - means the sum of R [●] ([●] Rand); 1.8 “Project” - means [insert if applicable.] 2. At the instance of the Contractor, we the undersigned ______________ and ______________, in

our respective capacities as _____________ and ___________ of the Bank, and duly authorized thereto, confirm that we hold the Guaranteed Sum at the disposal of Eskom, as security for the proper performance by the Contractor of all of its obligations in terms of and arising from the Contract and hereby undertake to pay to Eskom, on written demand from Eskom received prior to the Expiry Date, any sum or sums not exceeding in total the Guaranteed Sum.

3. A demand for payment under this guarantee shall be made in writing at the Bank’s address and shall:

3.1 be signed on behalf of Eskom by a Group Executive, Divisional Executive, Senior General Manager, General Manager or its delegate;

3.2 state the amount claimed (“the Demand Amount’); 3.3 state that the Demand Amount is payable to Eskom in the circumstances contemplated in



the Contract. 4. Notwithstanding the reference herein to the Contract the liability of the Bank in terms hereof is as

principal and not as surety and the Bank’s obligation/s to make payment: 4.1 is and shall be absolute provided demand is made in terms of this bond in all circumstances;

And

4.2 is not, and shall not be construed to be, accessory or collateral on any basis whatsoever. 5. The Bank’s obligations in terms of this Guarantee: 5.1 shall be restricted to the payment of money only and shall be limited to the maximum of the

Guaranteed Sum; and

5.2 shall not be discharged and compliance with any demand for payment received by the Bank in terms hereof shall not be delayed, by the fact that a dispute may exist between Eskom and the Contractor.

6. Eskom shall be entitled to arrange its affairs with the Contractor in any manner which it sees fit, without advising us and without affecting our liability under this Guarantee. This includes, without limitation, any extensions, indulgences, release or compromise granted to the Contractor or any variation under or to the Contract.

7. Should Eskom cede its rights against the Contractor to a third party where such cession is permitted under the Contract, then Eskom shall be entitled to cede to such third party the rights of Eskom under this Guarantee on written notification to the Bank of such cession.

8. This Guarantee: 8.1 shall expire on the Expiry Date until which time it is irrevocable; 8.2 is, save as provided for in 7 above, personal to Eskom and is neither negotiable nor

transferable;

8.3 shall be returned to the Bank upon the earlier of payment of the full Guaranteed Sum or expiry hereof;

8.4 shall be regarded as a liquid document for the purpose of obtaining a court order; and 8.5 shall be governed by and construed in accordance with the law of the Republic of South

Africa and shall be subject to the jurisdiction of the Courts of the Republic of South Africa.

8.6 Any claim which arises or demand for payment received after expiry date will be invalid and unenforceable.

9. The Bank chooses domicilium citandi et executandi for all purposes in connection with this Guarantee at the Bank’s Address.

Signed at _____________________ Date ____________________________ For and behalf of the Bank Bank Signatory: ___________________ Bank Signatory: ___________________

Witness: ________________________ Witness: _________________________



PART 2: PRICING DATA

ECC3 Option A

Document reference

Title No of pages

C2.1 Pricing assumptions: Option A

C2.2 The activity schedule


PART C3: SCOPE OF WORK PAGE 23 C3.1 ECC3 EMPLOYER’S WORKS INFORMATION

C2.1 Pricing assumptions: Option A

How work is priced and assessed for payment

Clause 11 in NEC3 Engineering and Construction Contract, (ECC3) Option A states: Identified and defined terms

11 11.2

(20) The Activity Schedule is the activity schedule unless later changed in accordance with this contract.

(27) The Price for Work Done to Date is the total of the Prices for Each group of completed activities and Each completed activity which is not in a group. A completed activity is one which is without Defects which would either delay or be covered by immediately following work.

(30) The Prices are the lump sum prices for each of the activities on the Activity Schedule unless later changed in accordance with this contract.

This confirms that Option A is a lump sum form of contract where the work is broken down into activities, each of which is priced by the tendering Contractor as a lump sum. Only completed activities are assessed for payment at each assessment date; no part payment is made if the activity is not completed by the assessment date.

Function of the Activity Schedule

Clause 54.1 in Option A states: “Information in the Activity Schedule is not Works Information or Site Information”. This confirms that specifications and descriptions of the work or any constraints on how it is to be done are not included in the Activity Schedule but in the Works Information. This is further confirmed by Clause 20.1 which states, “The Contractor Provides the Works in accordance with the Works Information”. Hence the Contractor does not provide the Works in accordance with the Activity Schedule. The Activity Schedule is only a pricing document.

Link to the programme

Clause 31.4 states that “The Contractor provides information which shows how each activity on the Activity Schedule relates to the operations on each programme which he submits for acceptance”. Ideally the tendering Contractor will develop a high level programme first then resource each activity and thus arrive at the lump sum price for that activity both of which can be entered into the activity schedule.

Preparing the activity schedule

Generally it is the tendering Contractor who prepares the activity schedule by breaking down the work described within the Works Information into suitable activities which can be well defined, shown on a programme and priced as a lump sum. The Employer, in his Instructions to Tenderers or in a Tender Schedule, may have listed some items that he requires the Contractor to include in his activity schedule and be priced accordingly. It is assumed that in preparing his activity schedule the Contractor:

Has taken account of the guidance given in the ECC3 Guidance Notes pages 19 and 20;



Understands the function of the Activity Schedule and how work is priced and paid for;

Is aware of the need to link the Activity Schedule to activities shown on his programme;

Has listed and priced activities in the activity schedule which are inclusive of everything necessary and incidental to Providing the Works in accordance with the Works Information, as it was at the time of tender, as well as correct any Defects not caused by an Employer’s risk;

Has priced work he decides not to show as a separate activity within the Prices of other listed activities in order to fulfil the obligation to complete the works for the tendered total of the Prices.

Understands there is no adjustment to the lump sum Activity Schedule price if the amount, or quantity, of work within that activity later turns out to be different to that which the Contractor estimated at time of tender. The only basis for a change to the Prices is as a result of a compensation event.

ITEM DESCRIPTION UNIT QTY RATE TOTAL

1 ASH HOPPER AERATION - WEST

1.1 Construction and Installation of works for Low Pressure Services on the aeration pads

Sum 1,00

2 ASH HOPPER AERATION - EAST

2.1 Construction and Installation of works for Low Pressure Services on the aeration pads

Sum 1,00

3 ASH HOPPER LEVELS

3.1 Construction and Installation of works for Low Pressure Services on the hoppers

Sum 1,00

4 Additional Scope

4.1 Modification and installation of additional lines, scopes in the LPS systems

Sum 1,00

5 Preliminaries and Generals

5.1 Allow for Preliminaries and Generals

% 20,00

Total excluding VAT



PART 3: SCOPE OF WORK

Document reference Title No of pages

This cover page 1

C3.1 Employer’s Works Information

C3.2 Contractor’s Works Information

Total number of pages



C3.1: EMPLOYER’S WORKS INFORMATION

Contents

Part 3: Scope of Work ..................................................................................................................................... 1

C3.1: Employer’s works Information ........................................................................................................... 26

1 Description of the works ...................................................................................................................... 30

1.1 Executive overview .......................................................................................................................... 30

1.2 Employer’s objectives and purpose of the works ............................................................................ 31

1.3 Interpretation and terminology ......................................................................................................... 31

2 Management and start up. ................................................................................................................... 31

2.1 Management meetings .................................................................................................................... 31

2.2 Documentation control ..................................................................................................................... 32

2.3 Health and safety risk management ................................................................................................ 33

2.4 Environmental constraints and management .................................................................................. 33

2.5 Quality assurance requirements ...................................................................................................... 33

2.6 Programming constraints ................................................................... Error! Bookmark not defined.

2.7 Contractor’s management, supervision and key people ................................................................. 37

2.8 Invoicing and payment ..................................................................................................................... 37

2.9 Insurance provided by the Employer ............................................................................................... 37

2.10 Contract change management ........................................................................................................ 38

2.11 Provision of bonds and guarantees ................................................................................................. 38

2.12 Records of Defined Cost, payments & assessments of compensation events to be kept by the Contractor..................................................................................................................................................... 38

2.13 Training workshops and technology transfer ..................................... Error! Bookmark not defined.

3 Engineering and the Contractor’s design .......................................................................................... 39

3.1 Employer’s requirements/design ..................................................................................................... 39

3.1.1 Design Codes............................................................................................................................. 39

3.1.2 Hopper level ............................................................................................................................... 39

3.1.3 Hopper aeration ......................................................................................................................... 39

3.1.4 Operating Philosophies .............................................................................................................. 40

3.1.5 Fire Protection ............................................................................................................................ 41

3.1.6 HVAC ......................................................................................................................................... 41

3.2 Parts of the works which the Contractor is to design ...................................................................... 44

3.2.1 Hopper level switches ................................................................................................................ 44

3.2.2 Hopper aeration ......................................................................................................................... 44

3.2.3 Fire Protection ............................................................................................................................ 44

3.2.4 HVAC ......................................................................................................................................... 45



3.2.5 Control and Instrumentation Engineering Works ....................................................................... 45

3.2.6 Civil engineering and structural works ....................................................................................... 51

3.3 Procedure for submission and acceptance of Contractor’s design ................................................. 52

3.4 Other requirements of the Contractor’s design................................................................................ 53

3.4.1 Responsibility for Design ........................................................................................................... 53

3.4.2 Engineering Documents ............................................................................................................. 53

3.4.3 Plant Coding Allocation .............................................................................................................. 53

3.4.4 Configuration change control ..................................................................................................... 53

3.4.5 Site Conditions ........................................................................................................................... 53

3.5 Use of Contractor’s design .............................................................................................................. 53

3.6 Design of Equipment ....................................................................................................................... 54

3.7 Equipment required to be included in the works ............................................................................. 54

3.8 As-built drawings, operating manuals and maintenance schedules ............................................... 54

4 Procurement .......................................................................................................................................... 56

4.1 People .............................................................................................................................................. 57

4.1.1 Minimum requirements of people employed on the Site ........................................................... 57

4.1.2 BBBEE and preferencing scheme ............................................... Error! Bookmark not defined.

4.1.3 Accelerated Shared Growth Initiative – South Africa (ASGI-SA) . Error! Bookmark not defined.

4.2 Subcontracting ................................................................................... Error! Bookmark not defined.

4.2.1 Preferred subcontractors ............................................................. Error! Bookmark not defined.

4.2.2 Subcontract documentation, and assessment of subcontract tendersError! Bookmark not defined.

4.2.3 Limitations on subcontracting ...................................................... Error! Bookmark not defined.

4.2.4 Attendance on subcontractors ................................................................................................... 56

4.3 Plant and Materials ............................................................................ Error! Bookmark not defined.

4.3.1 Quality .......................................................................................... Error! Bookmark not defined.

4.3.2 Plant & Materials provided “free issue” by the Employer ........................................................... 58

4.3.3 Contractor’s procurement of Plant and Materials ...................................................................... 58

4.3.4 Spares and consumables .......................................................................................................... 58

4.4 Tests and inspections before delivery ............................................................................................. 58

4.5 Marking Plant and Materials outside the Working Areas ................................................................. 58

4.6 Contractor’s Equipment (including temporary works). ..................................................................... 58

4.7 Cataloguing requirements by the Contractor ................................................................................... 58

5 Construction .......................................................................................................................................... 59

5.1 Temporary works, Site services & construction constraints ............................................................ 59

5.1.1 Employer’s Site entry and security control, permits, and Site regulationsError! Bookmark not defined.

5.1.2 Restrictions to access on Site, roads, walkways and barricades .............................................. 59

5.1.3 People restrictions on Site; hours of work, conduct and records ............................................... 59

5.1.4 Health and safety facilities on Site ............................................................................................. 59



5.1.5 Environmental controls, fauna & flora, dealing with objects of historical interest ...................... 59

5.1.6 Title to materials from demolition and excavation...................................................................... 59

5.1.7 Cooperating with and obtaining acceptance of Others .............................................................. 59

5.1.8 Publicity and progress photographs .......................................................................................... 60

5.1.9 Contractor’s Equipment ............................................................................................................. 60

5.1.10 Equipment provided by the Employer ........................................................................................ 60

5.1.11 Site services and facilities .......................................................................................................... 60

5.1.12 Facilities provided by the Contractor ......................................................................................... 60

5.1.13 Existing premises, inspection of adjoining properties and checking work of Others ................. 60

5.1.14 Survey control and setting out of the works ............................................................................... 66

5.1.15 Requirements during work ......................................................................................................... 67

5.1.16 Fabrication and Construction ..................................................................................................... 67

5.1.17 General ...................................................................................................................................... 68

5.1.18 Construction and Erection .......................................................................................................... 69

5.1.19 Excavations and associated water control ................................................................................. 66

5.1.20 Underground services, other existing services, cable and pipe trenches and covers ......... Error! Bookmark not defined.

5.1.21 Control of noise, dust, water and waste ....................................... Error! Bookmark not defined.

5.1.22 Sequences of construction or installation .................................................................................. 61

5.1.23 Giving notice of work to be covered up ...................................................................................... 61

5.1.24 Hook ups to existing works ........................................................................................................ 66

5.2 Data Books ...................................................................................................................................... 69

5.3 Completion, testing, commissioning and correction of Defects ....................................................... 69

5.3.1 Work to be done by the Completion Date .................................................................................. 69

5.3.2 Use of the works before Completion has been certified ............................................................ 62

5.3.3 Materials facilities and samples for tests and inspections ......................................................... 63

5.3.4 Commissioning .......................................................................................................................... 63

5.3.5 Start-up procedures required to put the works into operation ................................................... 64

5.3.6 Take over procedures ................................................................................................................ 71

5.3.7 Access given by the Employer for correction of Defects ........................................................... 65

5.3.8 Performance tests after Completion .......................................................................................... 65

5.3.9 Training and technology transfer ............................................................................................... 65

5.3.10 Operational maintenance after Completion ............................................................................... 66

6 Plant and Materials standards and workmanship ............................................................................. 69

6.1 General ............................................................................................................................................ 69

6.2 Investigation, survey and Site clearance ......................................................................................... 69

6.3 Building works .................................................................................................................................. 70

6.4 Civil engineering and structural works ............................................................................................. 70

6.4.1 Additional Requirements and Specifications ............................................................................. 71



6.4.2 Concrete ..................................................................................................................................... 71

6.4.3 Structural Steelwork ................................................................................................................... 73

6.4.4 Corrosion protection ................................................................................................................... 74

6.5 Mechanical engineering works ........................................................................................................ 74

6.5.1 General Requirements ............................................................................................................... 74

6.5.2 Specific Requirements ............................................................................................................... 75

6.5.3 HVAC specific requirements ...................................................................................................... 77

6.5.4 Particular Specifications pertaining to SANS 2001 .................................................................... 89

6.5.5 Tests and Inspections ................................................................................................................ 89

6.6 Electrical engineering works ............................................................................................................ 89

6.7 Process control and IT works .......................................................................................................... 90

6.8 Plant labelling and descriptions ....................................................................................................... 90

6.9 Other [as required] ........................................................................................................................... 90

7 List of drawings..................................................................................................................................... 91

7.1 Drawings issued by the Employer ................................................................................................... 91

Appendix A : Document Descriptions ......................................................................................................... 92



C3.1: Employer’s works Information

1. Description of the works

1.1. Executive overview

Camden P. S. is located approximately 15 km to the South East of the town of Ermelo in the Mpumalanga province and has a production capacity of 1 600 MW. The station has eight (8) 200 MW units, with the first unit commissioned in 1967. Half of the station was mothballed in 1988 with the rest of the station following suit in 1990. In 2003 the station was re-commissioned as a result of the increase in the electricity demand with the first unit re-commissioned in 2005. The first unit is expected to be decommissioned in 2027 and the last unit decommissioned in 2030.

Due to deteriorating coal qualities with high ash content resulting in higher quantities of ash produced, the existing Ash Dam facility is estimated to reach end of life. This resulted in the need for the construction of a new Ash Dam. The Ash Handling Plant (AHP), thus also needs to be upgraded to convey the ash to the new Ash Dam.

The works include: Hopper aeration system

Aeration blowers with associated piping, filters, valves and instrumentation.

Heaters

Distribution piping with associated valves and instrumentation

Hooper aeration pad supply piping with associated valves and instrumentation

Hooper aeration pads

Thermal insulation

Modification to hoppers

Control Air supply with associated piping, filters, valves and instrumentation

Hopper level switches and associated piping including modification to hoppers

HVAC

West Aeration Substation

East Aeration Substation

Unit 1 to 4 Hopper Aeration Blower Houses


Fire Protection





C&I field equipment

The C&I scope of work for this work package shall be the engineering, procurement and installation of field instrumentation from field to field junction box including terminating inside the junction box. The field instrumentation will include the associated Electrical circuit, fire detection and HVAC systems

Electrical field equipment

Civil

All required civil modifications

Assess the current buildings for any defects

Provides design assurance that the buildings have been constructed as per design

Issues the Employer with a completion certificate for the buildings



1.2. Employer’s objectives and purpose of the works

The objective of the project is to upgrade and/or install new Plant and Materials for the AHP to achieve:

The ash disposal system, to enable it to dispose of all ash produced in the available plant operation time, to the new Ash Dam.

The AWR and SWS systems to support the return of decanted water from the new Ash Dam to be reused in plant operations.

1.3. Interpretation and terminology

The following abbreviations are used in this Works Information:

Abbreviation Meaning given to the abbreviation

AFC Approved for construction

AWR Ash Water Return

HVAC Heating Ventilation and Air Conditioning

LPS Low Pressure Services

OBL Outside battery limits

2. Management and start up.

2.1. Management meetings

Regular meetings of a general nature may be convened and chaired by the Project Manager as follows:

Title and purpose Approximate time & interval

Location Attendance by:

Risk Meeting Every two weeks Camden Power Station Project Manager Supervisor SHE officer Contractor

Overall contract progress and feedback

Monthly Camden Power Station Project Manager Supervisor SHE officer Contractor Finance /QS

Health, Safety and Environmental meetings

As stipulated (SHE specification

Camden Power Station Project Manager Supervisor SHE officer Contractor

Assessment meetings

Monthly on or before 25th of each month

Camden Power Station Project Manager Supervisor Finance/QS Contractor

Planning and Scheduling

Weekly Camden Power Station Project Manager Supervisor Finance/QS Contractor



Any adhoc meetings can be called by either party at any stage as and when required. All meetings shall be recorded using minutes and an attendance register prepared and circulated by the person who convened the meeting. Such minutes or register shall not be used for the purpose of confirming actions or instructions under the contract as these shall be done separately in terms of the contract.

2.2. Documentation control

The documentation requirements cover the various engineering stages, from the design stage through fabrication, installation, testing and commissioning and most importantly for the operating, maintenance and training stage of the project. The Contractor is responsible for the compilation and the supply of the documentation for all and during the various project stages and to provide the documentation programmed to link with the milestone dates. Documentation and drawings are programmed for delivery to meet the milestone dates and in accordance with the agreed Vendor Document Submittal Schedule (VDSS) Appendix A. Contractual Communication

Properly compiled letters on official Company letter head or forms attached to an e-mail and not as a message in an e-mail itself.

Alpha numeric identification – Reference: Date/Project Name/Communication number e.g. 2020-10- 23/Civil /012 shall be used.

Site Communication

Contractor daily site diary signed daily by the Supervisor.

Site memorandums addressed to the Supervisor.

Daily Site Diaries This shall be a suitable carbon copy book, with two detachable sheets for a page per day where all events affecting execution of the works, such as arrivals of plans, breakdown of Equipment, weather conditions etc., are entered. The Contractor keeps these records and submits copies of these records to the Supervisor on a weekly basis in the form of these daily site diaries and shall contain, but not limited to the following information: a) Contract Number b) Date c) Work Hours – Start, Finish and Overtime d) Rainfall (mm) e) Temperature f) Visitors to site g) Contractor’s employees on site and description (Site Agent, Foreman, Skilled, etc.) h) Subcontractors

i) List of Plant and Equipment by category on site on a daily basis with an indication of its working condition i.e. working order, under repair, working but standing idle etc.

j) Brief description of the day’s activities k) Toolbox talk topic l) Diary must be signed daily by both the Contractor & Supervisor Document identification The Contractor is required to submit the Vendor Document Submission Schedule (VDSS) as per agreed dates with the Project Manager. The Project Manager will pre-allocate document numbers on the VDSS and send back to the Contractor. The VDSS is revisable and changes must be discussed and agreed by the Contractor and Project Manager. Changes in the VDSS can be additional documentation to be submitted, changes in submission dates or corrections in documentation descriptions, document numbers, etc. Documents Submission



All project documents must be submitted to the Project Manager with transmittal note according to Project / Plant Specific Technical Documents and Records Management Work Instruction (240-76992014) latest Rev In order to portray a consistent image it is important that all documents used within the project follow the same standards of layout, style and formatting as described in the Work Instruction above. The Contractor is required to submit electronic documents using CD/DVD, e-mail and/or drives. Hard copies must be delivered to the Project Manager with the transmittal note

2.3. Health and safety risk management

The Contractor shall comply with the health and safety requirements contained in Appendix F of this Works Information. The Contractor shall be certified or comply with SHE System (OSHAS 18001 and ISO14001). The Contractor shall comply with the Employer’s SHE Specification, applicable legislation, Eskom Standards and Procedures.

2.4. Environmental constraints and management

The Contractor shall comply with the environmental criteria and constraints stated in Appendix F of this Works Information. The Contractor will comply with the Employer’s requirements (including: the permit conditions, IEA, EMPr, and applicable Environmental Procedures).

2.5. Quality assurance requirements

2.5.1. General The Contractor complies with the Eskom Quality Requirements Standards.

a) The Contractor and all subcontractors comply with the Employer’s quality requirements including those listed in the Employers specification document, QM 58.

b) Certified to ISO 9001 is a mandatory requirement for this contract. The Contractor uses the QMS for all phases of the Project. The Contractor provides evidence of a fully implemented QMS within its own organisation. The Employer may, at his sole discretion, carry out an audit on the Contractor or Subcontractor’s QMS for acceptance.

2.5.2. Quality Management Documents Requirements The Contractor conforms to the quality management requirements as per ISO 9001 and the Employer’s Supplier Contract Quality Requirements Specification (QM 58 or 240-109253302). The Contractor submits documentation as stipulated in QM58, that is:

a) Documents to be submitted during tender stage, b) Documents to be submitted 30 Days of Contract Date, c) Documents to be submitted during execution of the contract, and d) Documents to be submitted on completion of the contract.

2.5.3. Quality Control Plan or Inspection and Test Plan

As defined in the approved CQP the Contractor drafts and submits to the Project Manager for acceptance, prior to the commencement of any works, the requisite Inspection and Test Plan (ITP) or Quality Control Plan

(QCP). The ITP/QCP shows each activity from the Works Information. The Project Manager inserts intervention points based on the risk profile of the equipment.



a) The interventions points include all witness, hold, verification, surveillances and review points required by the Project Manager. The Contractor’s failure to allow the intervention points will constitute a non-conformance.

b) The intervention requirements take into consideration the criticality of the Plant and Materials.

c) Where intervention points have been bypassed without prior written waver from the Project Manager, result in the repeat performance of the activity in question and a Non-conformance (NC) is issued.

2.5.4. Operational Documents The Contractor submits as a minimum the following documents, as required by the Project Manager during the execution of the works:

a) Updated QCP register

b) Inspection notifications accompanied by their inspection report

c) Non-conformance and Defects registers and reports

d) Updated Site and off site inspection schedules.

e) Inspection and or FAT / SAT dates f) Inspections, completed and outstanding.

g) Inspection and test reports

h) Weekly and monthly contract quality progress report

i) Data books for the completed works, before commissioning can commence (refer to the data book

specification)

2.5.5. Inspections and Tests

All Plant and Materials is comprehensively tested in accordance with the agreed ITP/ QCPs prior to delivery. The Employer reserves the right to appoint Others to inspect all parts during manufacturing, erection and commissioning to be present at any of the tests specified. The witnessing of tests by the Supervisor or Others, and if the Supervisor chooses to waive the witnessing of any tests, it does not relieve the Contractor of his responsibilities. Tests that are required by the Employer are carried out by the Contractor during manufacturing, erection and commissioning to prove compliance with the specification independently of any test that may have been carried out at the Contractor’s premises. The Supervisor inspects parts of the Plant at his discretion during manufacturing stages and before shipment as per the agreed ITP/QCP;

a) The Contractor is responsible for the inspection of all the work that is performed and the Supervisor only verifies that the work is conducted as per the Works Information.

b) The Contractor conducts all inspections in accordance with the accepted ITP/QCP. c) The Contractor provides suitably qualified personnel to conduct on-and-offsite inspections

d) The Contractor ensures that all are inspected and approved before the Supervisor is invited for verification. e) The Contractor provides a minimum of 5 working days’ notice for local off-site inspections, 24 hours for local on-site inspection, and 21 working days’ notice for foreign inspections. The notice contains copies of the Contractor’s inspection reports.

2.5.6. Quality Responsibility The Contractor responsibilities include but are not limited to the following: a) The Contractor is accountable for the quality of the output and liable for any failures. b) Implementation of their QMS on site

c) Administration of their QA/QC systems on site



d) Verification of approval status of Subcontractor’s Quality programmes, that is, CQP’s, QCPs, NC’s, Defects and all their operational procedures and works instructions e) On-and-offsite inspections f) Weekly and monthly progress reporting on quality performance g) The Contractor is responsible for defining the level of intervention of QA/QC or inspections in line with the Employers requirements. h) The Contractor is responsible for defining the level of intervention of QA/QC or inspections to be imposed on his Subcontractor, suppliers and sub-suppliers and must ensure that these are in line with the Employer’s requirements.

The Supervisor will be responsible for the following:

a) Reviews of the quality submissions b) Verification of the Contractor’s intervention points c) Reviews the Contractor’s ITP/QCP documents (procedures, test results) d) Reviews the data book

2.5.7. Non-Conformances

Where Non-Conformance (NC) notifications are issued, the Contractor acknowledges receipt within the period of reply and proposes corrective and preventive actions to the Supervisor. The corrective and preventive actions will include the implementation and completion dates. Progress on all NCs notifications issued to the Contractor must be reported to the Supervisor on weekly basis. a) The Contractor’s Quality Manager keeps a register of all NC notifications issued b) Records of NCs notifications are kept and form part of the data book records. During the contract execution phase, the Contractor will be monitored by the Supervisor for performance on quality related aspects. The monitoring will be in the form of audits and assessments.

2.5.8. Quality Reporting The Contractor submits a monthly quality report, on the last working day of the month. The report includes but not limited to the following: a) A register of NCRs and defects b) Updated QCP / ITP register c) QA monthly report summary d) Planned and completed local and foreign inspection dates e) Completed and outstanding Inspections f) Audit findings report

2.5.9. Preservation and transportation The Contractor ensures that all equipment is preserved in an appropriate manner as described in the product specifications or in Eskom preservation and transportation procedures as applicable. The Contractor submits the preservation and transportation procedures to the Supervisor for review and acceptance. The Supervisor may choose to witness the packaging, loading and offloading of the products depending on the equipment criticality, this will be indicated in the intervention points on the ITP/QCP. The Contractor also ensures that all storage requirements for equipment are properly implemented to preserve the products against adverse conditions, deterioration, damages, etc. Storage and preservation procedures for the different equipment must be submitted to the Project Manager for review and acceptance. The Project Manager may request to inspect the stored equipment at any given point during the storage period of the product. The Contractor shall comply with the quality criteria and constraints stated in QM 58 of this Works Information.



2.6. Programming constraints

The Contractor shall comply with the requirements as set out in the Employer’s document. The programme is to be submitted for Acceptance in accordance with the NEC3 Engineering and Construction Contract. It is required that Primavera P6 be used for project planning and scheduling, while progress graphs/schedules be submitted at bi-weekly project meetings to monitor progress.

A Planning Requirements

A.1 Schedule submitted using latest version of Primavera. The programme submitted is at least detailed up to level 3 in both PDF and XER file

Progress "S" curves, including early /late plan forecast and actual progress percentages to be attached to programme submissions

A.2 Critical Path Method (CPM) to be used clearly indicating the Critical Path and near critical path .Activity durations are shown in Days (and hours if required).Commissioning activities shown in hours.

A.3 The calendar must be clearly shown and must be 7 days a week, 8 hours a day , indicating pay weekend (negotiable)

A.5 Schedule includes activities to the Sub-system/Work Package level on the Works Information Package level

A.6 The schedule also includes all procurement activities, quality hold points and Engineering hold point and reviews

A.7 Method statement to be submitted, this must align with Project activities

A.8 Schedule is resource loaded including but not limited to Engineering , Construction and Commissioning for evaluation purposes, activities are WBS coded, and Activities align with the method statement

The following must be in the programme:

A.9 a) All project Milestones i.e. Procurement , Manufacturing, Inspections & Test, Delivery etc.

b) Project Key dates

c) Engineering and Quality hold point milestones

d) Interface dates

e) Commissioning Key Dates



A.10 Schedule Basis Document has to accompany the initial and all updated schedules to provide the project team of changes and their effect, if any on the schedule time frame The information must include but not limited to all key assumptions, constraints and measurement :nonworking days, daily working hours and shifts for different resources and activities, resources KPI measurement and rates on how resource efforts are linked to durations and availability , resource histograms, progress measurement basis and in conjunction with Earned Value Management and resource levelling assumptions and setting on Primavera program

2.6.1. Progress

The Contractor monitors progress weekly in conjunction with the Supervisor. A weekly progress report is to be submitted to the Project Manager every Thursday at 10:00 AM.

2.7. Contractor’s management, supervision and key people

The Contractor is to submit 7 days after Contract Date, an organogram clearly indicating the reporting lines from the Contractors’ top management to the Supervisor level and all contact information.

2.8. Invoicing and payment

The Contractor shall address the tax invoice to Eskom Holdings SOC Ltd and include on each invoice the following information:

Name and address of the Contractor and the Project Manager;

The contract number and title;

Contractor’s VAT registration number;

The Employer’s VAT registration number 4740101508;

Assessment Certificate;

Goods Receipt (GR) Number

Description of service provided for each item invoiced based on the Price List;

Total amount invoiced excluding VAT, the VAT and the invoiced amount including VAT;

All invoices in PDF format shall be emailed straight from your system to an Eskom email address (see email addresses below):

Email address for invoice submission:

All invoices to [email protected]

The Project Manager shall be copied when submitting invoices.

2.9. Insurance provided by the Employer

All queries and follow up on invoice payments should be made by contacting the FSS Contact

Centre: Tel: 011 800 5060 or e-mail: [email protected]

For Foreign invoices, the Contractor is required to physically deliver hard copies of original documents to the Project Manager even though the Contractor has e-mailed those invoices.

The Contractor ensures compliance with the tax Requirement for submitting invoices electronically.

Electronic invoicing does not guarantee payment but ensures visibility of all invoices and ensures that no invoices get lost. If the goods receipt (GR) is not done the invoice will be parked and the system will automatically send an e-mail to the Project Manager to do the goods receipt. This is also tracked by the Employer through the parked invoice report.



The Contractor can request a parked invoice report from the Finance Shared Services (FSS) Contact Centre which can then be followed up and corrected. You are welcome to forward the details of invoices corrected to the FSS Contact Centre.

2.10. Contract change management

N/A

2.11. Provision of bonds and guarantees

The form in which a bond or guarantee required by the conditions of contract (if any) is to be provided by the Contractor is given in Part 1 Agreements and Contract Data, document C1.3, Sureties. The Employer may withhold payment of amounts due to the Contractor until the bond or guarantee required in terms of this contract has been received and accepted by the person notified to the Contractor by the Project Manager to receive and accept such bond or guarantee. Such withholding of payment due to the Contractor does not affect the Employer’s right to termination stated in this contract.

2.12. Records of Defined Cost, payments & assessments of compensation events to be kept by the Contractor

i. No standing time claims will be entertained without the relevant proof of presence and activity in the form of a time sheet. ii. Proof of expenses must be provided to the Employer as a hard copy as well as a soft copy.



3. Engineering and the Contractor’s design

The Contractor submits the documents specified in the VDSS to the Project Manager for acceptance.

3.1. Employer’s requirements/design

3.1.1. Design Codes

The works is designed in accordance with the following design codes:

SANS 347, Categorization and conformity assessment criteria for all pressure equipment

3.1.2. Hopper level

Each hopper is provided with two (2) additional level measurements.

The vacuum type level switch hopper level measurement system has been partly constructed by others. The Contractor performs an assessment on the part of the works already constructed by others and corrects all defects. The assessment includes a pressure test.

3.1.3. Hopper aeration

The hopper aeration system has been partly constructed by others. The Contractor performs an assessment on the part of the works already constructed by others. The assessment includes a flow analysis to verify all system parameters and a pressure test.

Hopper aeration design parameters

Aeration Pad Size 0.0456 m2

Aeration Rate * 2 m3/min/m2

No. off hoppers aerated simultaneously 4

No. off pads per hopper 4

Safety Factor 50% %

Site Altitude 1 670 m.a.m.s.l.

Min Site Temperature (As per SOW) 0 oC

Max Site Temperature (As per SOW) 24.7 oC

Required Pressure 20 kPa

Minimum Discharge Pressure 5 kPa

Required Temperature 110 oC

Blower Temperature Increase at 5 kPa 7.5 oC

Air Specific Heat 1.012 kJ/kg.K

Pressurised air, for the purposes of aerating the ash in the hoppers, is supplied to through blowers. One blower supplies air to the ash hoppers for two units. For each blower supplied, a standby unit will also be installed.

Based on the sluicing philosophy, four (4) hoppers per ash sump will be aerated simultaneously. I.e. for each set of two (2) units, Units 1 & 2, 3 & 4, 5 & 6, and 7 & 8, four (4) hoppers will be aerated. One (1) blower will be dedicated to each set of units. For each blower a standby blower will be available.



Hoppers must only be aerated while being discharged.

The Contractor

Supply and install four (4) hopper aeration pads, one (1) in each valley. of the lower part of the FFP hoppers

Modify the existing ash hoppers to enable fixing of the hopper aeration pads.

Connects the aeration pad to the distribution piping (constructed by Others)

Supply and install thermal insulation from the heaters up to where the piping enters the hopper.

Correct all defect on the part of the works constructed by Others.

3.1.4. Operating Philosophies

General

Each blower house has two (2) operating (primary) and two (2) standby (secondary) blowers with each operational blower sized to supply the aeration air requirements for two (2) units

Once a week the primary blower shuts down and the secondary blower starts up, the secondary blower operates for twenty four (24) hours after which it will shut down and the primary blower will start up.

The entire change over process from the primary to secondary blower and vice versa is achieved automatically by the control system.

At no point in the changeover process is there to be a loss of air supply to the hopper aeration system.

The air heaters for the hopper aeration system are constructed of multiple banks, each bank is able to be activated and deactivated as required to ensure that the temperature of the air supplied to the aeration pads within the hoppers is at the required temperature.

The operation of the heater banks are fully automated by the control system.

Start Up

The blower house pressurisation fans runs continuously thus providing suction air for the blowers and air to pressurise the blower house to keep out dust and ash contaminants.

During start-up of the boiler the hopper aeration system will start.

The hopper aeration system for the unit is in full operation and operating at the correct temperature before the first ash is deposited within the FFP hoppers.

The hopper aeration system follows a set automated start up sequence that is controlled from the DCS.

If the hopper aeration system is not available, there are no interlocks that prevent any other plant areas from starting up.

Shutdown

The hopper aeration system remains in operation while the unit is shutting down and only shuts down once the hoppers have been emptied and dusting is completed.

When shutting down the hopper aeration system follows an automated shut down sequence.

Condition Monitoring

Local monitoring is centralised on a common local instrument panel. The following indications are provided as a minimum:

Air delivery pressure.

Temperature and flow transmitters.

Lubricating oil pressure.

Temperature and oil filter pressure drop (if applicable).

Motor running current (preferably power) and running hours.

Vibration monitoring.

Intake filter pressure drop.



User consumption monitoring using flow transmitters.

Any other required by virtue of the design.

3.1.5. Fire Protection

The Contractor performs a fire protection/detection assessment in accordance with 240-54937439, “Fire Protection/Detection Assessment Standard” and implement the recommendations. The Contractor considers all adjacent plant in determining the worst case scenario.

3.1.6. HVAC

The HVAC system have been installed but not commissioned. The Contractor performs an assessment on the part of the works already constructed by Others and submits a report to the Project Manager. The report makes recommendation to rectify all the defects and deficiencies.

Outdoor design conditions:

Summer: 32°C DB, 20°C WB

Winter: 2°C DB

Altitude: 1630 m

Electrical Switchgear and C & I Equipment rooms

The areas include:



The areas are air conditioned with the direct expansion system (Dx.), comprising of a package cooling unit, ducted supply and return air with a return air fan

The package units are positioned external to the building rooms to withstand the prevailing conditions at Camden Power Station.

The temperature in the Switchgear rooms, C & I equipment rooms, is designed at 22 ± 2 °C and 50% RH in summer and in winter.

The minimum filtration efficiency complies with MERV-9 as defined in ASHRAE 52.2-2007.

The velocity across the filters is less than 2.5 m/s.

The total unit cooling and heating capacity should include for the equipment load, building load, fresh air load at design parameters and the unit inefficiencies.

The system is equipped with a flow monitoring device to indicate when the filters are blocked or the fan unit has failed.

The design life of the HVAC system is 15 years.

The Contractor makes provisions for a dirty/blocked filter alarm to be interfaced with the station AHP DCS (Done by Others)

Concrete plinths for major equipment and steel base frame are provided. The floor level has a sloping gradient to prevent water flooding

Ventilated areas

The areas include:





The Hopper Aeration Blower Houses are ventilated with filtered fresh air, via 2 x 100% axial fans. The fans are positioned at high level with permanent access platform for maintenance purposes. Louvers are installed at high level to relieve the air pressure in the rooms.

HVAC system performance requirements

System Performance Requirements: West Aeration Substation

3.1. Type of equipment Package cooling unit (Heat pump or similar)

3.2. Number of equipment 2 x 100%

3.3. Room size (Area x height) 67.2m2 x 4m

3.4. Indoor design temp (summer and winter). 22 ± 2 °C DB 50%RH

3.5. Specified supply air quantity 1.2m3/s

3.6. Cooling duty required at site conditions 33kW

3.7. On coil condition 24°C DB /15°C WB

3.8. Off coil condition 10.5 °C DB / 9°C WB

3.9. LP protection Supplier to advise

3.10. Filtration requirement (Primary & Secondary) G3 & F9 filters

3.11. Available pressure drop (Pa) 400Pa

3.12. Electrical requirements (kW) Supplier to advise

3.13. Outdoor installation (Y/N) Yes

3.14. Operation weight (kg) and foot print(m x m) Supplier to advise

Note: a) The package unit is positioned on ground floor and external to the substation b) The system is ducted external to the rooms as per the abovementioned supply air quantities.

System Performance Requirements: West Aeration Substation

4.1. Type of equipment Axial Fan

4.2. Number of Fans 1

4.3. Air flow rate (approx) (m3/s) 1 m3/s

4.4. Static Pressure (Pa) 450 Pa

Note: N/A.

System Performance Requirements: East Aeration Substation

5.1. Type of equipment Package cooling unit (Heat pump or similar)

5.2. Number of equipment 2

5.3. Room size (Area x height) 67.2m2 x 4m



5.4. Indoor design temp (summer and winter). 22 ± 2 °C DB 50%RH

5.5. Specified supply air quantity 1.2m3/s

5.6. Cooling duty required at site conditions 33kW

5.7. On coil condition 24°C DB /15°C WB

5.8. Off coil condition 10.5 °C DB / 9°C WB

5.9. LP protection Supplier to advise

5.10. Filtration requirement (Primary & Secondary) G3 & F9 filters

5.11. Available pressure drop (Pa) 400Pa

5.12. Electrical requirements (kW) Supplier to advise

5.13. Outdoor installation (Y/N) Yes

5.14. Operation weight (kg) and foot print(m x m) Supplier to advise

Note: a) The package unit is positioned on ground floor and external to the substation b) The system is ducted external to the rooms as per the abovementioned supply air.

System Performance Requirements: East Aeration Substation

6.1. Type of equipment Axial Fan


6.3. Air flow rate (approx) (m3/s) 1 m3/s

6.4. Static Pressure (Pa) 450 Pa

Note: N/A.

System Performance Requirements: Unit 1 – 4 Hopper Aeration Blower House

15.1. Type of equipment Axial Fans


15.3. Air flow rate (approx) (m3/s) 3.2 m3/s

15.4. Total Pressure 260Pa

15.5. Material Used Supplier to advise

15.6. Standard Finish Supplier to advise

Note: N/A


16.1. Type of equipment Louvers

16.2. Number of Louvers 2




Note: N/A.




17.1. Type of equipment Axial Fans



17.4. Total Pressure 260Pa



Note: N/A


18.1. Type of equipment Louvers

18.2. Number of Louvers 2




Note: N/A

HVAC System Interface

The interface with the fire system to must go through a potential free contact receiving signal from the fire detection panels via hard wired links.

3.2. Parts of the works which the Contractor is to design

3.2.1. Hopper level switches

The Contractor implements the outcome of his assessment and submits a design for any required modifications. The Contractor designs the hopper level measurement system for the remainder of the Units.

3.2.2. Hopper aeration

The Contractor implements the outcome of his assessment and submits a design for any required modifications.

The Contractor designs the remainder of the hopper aeration system.

The following documents include the part of the works already constructed by Others and the hopper level measurements:

Process Design Report

Process flow diagrams

P&ID’s

Control Philosophy

Equipment lists/Label list

Control & Instrumentation Instrument Schedule

Control & Instrumentation Drive & Actuator Schedule

Panel interface list

Electrical Load List

Mechanical Equipment lists/Schedules

3.2.3. Fire Protection



The Contractor implements the recommendations from the Fire protection and detection assessment submit a design for any required modifications.

3.2.4. HVAC

The Contractor implements the outcome of his assessment and submits a design for any required modifications.

The Contractor is responsible for the detailed design of the HVAC Works based on the information supplied in the Works information and the Contractor’s assessment of the part of the works already constructed by others.

The design data specified in this works information are verified by the Contractor. The Contractor is required to take the actual measurements onsite before proceeding with design & manufacture of the HVAC Works as dimension accuracy remains the responsibility of the Contractor.

The minimum general equipment design criterion that is to be met is as follows:

The equipment is designed to facilitate efficient manufacture, inspection, transportation, installation, maintenance, cleaning and repairs.

The equipment is designed to ensure safe and satisfactory operation for a life expectancy of at least 15 years for the HVAC equipment under the conditions prevailing at Camden Power Station site. The life expectancy of the pipe work and associated fittings must suffice for the remaining life of the station

The equipment is designed to prevent undue stresses being produced by expansion and contraction due to temperature change and other local natural and manmade conditions.

The equipment is designed to keep maintenance costs to a minimum.

The equipment is designed to comply with all the legal requirements in respect of safety and the prevention of environmental pollution.

The equipment is designed to satisfy any specific requirements contained in the relevant statutory codes and standards.

The equipment is designed for operation of 365 day per annum, 24hrs per day.

The equipment is designed such that all material from which the equipment are manufactured from is compatible with the intended duty and service conditions. All equipment is suitable treated and protected from corrosion.

All electrical equipment, forming part of the specified equipment are sealed against penetration by hose cleaning operations, and be also accessible for repair and maintenance.

The details of equipment and installation requirements are specified in section 6.5.3.

3.2.5. Control and Instrumentation Engineering Works

The C&I scope of work for this work package shall be the engineering, procurement and installation of field instrumentation from field to field junction box including terminating inside the junction box. The field instrumentation will include the associated Electrical circuit, fire detection and HVAC.

The boundaries of these installations (depending on the installation) are the Junction box, and tapping points. C&I Field Scope Boundary LOSS Diagram shall be provided to the Contractor to redline and submit to the Engineer for approval.

3.2.6. Control and Instrumentation Field Specification

1. The Contractor shall be responsible for Engineering, selection and installation of all field protection devices, field instruments, field cabling from field to the field junction boxes.



2. The Contractor shall be responsible for the guarantees of all instruments, safety devices, protection systems and other equipment supplied by Others under this works.

3. Equipment supplied shall be standardised to match as far as possible with what the site currently uses. This shall aid with maintenance, spares holding and training as plant personnel have been trained on the current equipment and devices. A comprehensive spares list, as proposed by the OEMs and best maintenance practices, shall be supplied. The new plant shall also have the capability to interface with the DCS.

4. All equipment shall be installed in accordance with the manufacturer’s instructions, listed standards and industry best practices. Additional protection hoods and enclosures must protect those transmitters situated outdoors or in adverse environments. In addition, earthing concepts shall follow the OEM best practices and Employer standard 240-56356396 Earthing and Lightning Protection Standard to ensure safe and reliable operation

5. The Contractor provides power for all non-loop powered instrumentation.

6. The Contractor provides power for all field instrumentation.

7. The Contractor shall specify Instruments of high accuracy and high quality. Instruments that require an external power supply shall be configured to accept 24VDC power. If a 24VDC power option is not available, 230VAC is acceptable.

8. All cabling and cable racking shall adhere to Eskom standard 240-56227443 Requirements for Control and Power Cables for Power Stations Standard. Instrument cabling will be installed with due respect for safety, reliability, access, maintenance, environmental conditions and best practices. All cabling will be suitably protected against mechanical damage, chemicals, dust build-up and heat.

9. The scope of cabling that is defined as:

a. Instrument cabling defined as cabling between protection field instruments as well as cabling between the non-protection field instruments and junction boxes.

b. Power supply cabling is defined as being cabling required to power field equipment.

c. Cables shall only be terminated in instruments, junction boxes. No intermediate cable joints are permitted.

d. Cables connected to instruments are installed with a loop of cable to provide sufficient slack for re-making the cable connection if the instrument is removed and to allow for removing the instrument without electrical disconnection.

e. Instrument cables are routed separately from electrical power cables and crossovers that bring signal and power cables into close proximity are made at right angles

f. The routes for power supply cabling and the racking are of a consistent and integrated design taking into account different cabling and racking routes for common modes of failure, and the redundancy concepts of the mechanical plant design.

g. The Contractor provides 20% spare installed capacity in all multi-core cables, rounded up.

10. The Contractor provides cable schedules inclusive of origin, target, type, and size specification.

11. The Contractor provides termination schedules for all cables that form part of the works.

12. Unless otherwise stated in these Employer’s Requirements, the Works shall be tested in accordance with the requirements and procedures approved by the Engineer. To this end the Contractor shall submit his proposed requirements and procedures for all tests (including for the Tests on Completion and the Tests after Completion) to the Engineer. These requirements and procedures shall be developed so as to suitably and properly demonstrate that the Works meet the Employer’s Requirements and shall:

a. be in accordance with the details (if any) stated in the Contract; and

b. be further developed or amended and re-submitted at the expense of the Contractor until they are approved by the Engineer

Testing shall adhere to at least the minimum requirements set by IEC 62381 (Automation systems in the process industry - Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT))



13. The Contractor shall list all drives and actuators in the “C&I Templates: Drive and Actuator list” and shall motivate the use of all non-electrical actuators as indicated in the “C&I Templates: Drive and Actuator list” in the REMARKS/MOTIVATIONS column, for the Engineer’s approval.

14. The Contractor shall compile an Instrumentation Schedule and a Drive & Actuator Schedule for his design that shall be submitted for approval by the Employer.

15. The Contractor shall be provided with the following relevant Employer’s standards and guidelines: a. 240-56355815: Field Instrument Installation for Junction Boxes and Cable Termination

Standard

b. 240-56227443: Requirements for Control and Power Cables for Power Stations Standard

c. 240-56355815: Control & Instrumentation Field Enclosures and Cable Termination Standard

d. 240-56356396 Earthing and Lightning Protection Standard

e. 240-56355466: Alarm Management System Guideline

f. 240-56737448, Fire Detection and Life Safety Design Standard

16. The Contractor shall provide the Operating and Control philosophies and the associated P&IDs. The Operating and Control philosophy shall highlight the intent of safely and optimally operating the plant system as per the:

a. Automatic mode

b. Manual Mode

c. Maintenance Mode

d. plant preparation for start-up

e. plant start-up

f. plant running

g. plant shut-down

h. Power plant operation during incidents

The command and monitoring operator intervention actions, interfaces and alarms shall be considered during the above conditions to enable effective overall plant control

17. The Contractor shall ensure that all C&I equipment is properly labelled with permanent labels that will not be effortlessly removed. All the labelling shall comply with Camden KKS coding requirements. Field device labels must be made of stainless steel, text on labelling be engraved. The label shall cover the following as a minimum:

a. KKS Code

b. Plant Description

c. Zone Classification (Safety Hazard Level)

d. Instrument type

e. Instrument Range

f. Technical Data

All labels mounted on the instrument racks shall show the KKS code of that instrument 18. Local alarm indicators on the control panel are provided for all conditions likely to lead to failure of the

drive. The annunciation of alarms gives a visible alarm panel light on the control cubicle. Once the alarm condition has been corrected, the operator is able to reset the alarm

19. The Employer’s project manager shall provide the list of “free issue” list of Instrumentation for the project.

Protections and Alarms Specification

(1) The system will include all the protections and alarms as detailed in the control philosophy.



(2) The protections and alarms and their response actions are to be specified and documented according to the Employer’s Alarm Management System Guideline 240-56355466.

(3) A comprehensive and integrated alarm handling system shall be employed.

(4) The alarm handling system shall clearly distinguish between different alarm types and provide alarm filtering functionality.

(5) Alarm information shall not be lost or inaccessible whilst navigating through displays. Alarm presentation shall be dynamically provided to the operator with information matched to the current situation and its criticality.

(6) The alarming shall comply with the requirements of 240-56355466 - Alarm Management System Guideline.

(7) Nuisance alarms shall not be repeated on the alarm pages.

(8) Users shall be able to navigate directly from any alarm to the alarm response sheet for that specific alarm.

(9) Alarm response sheets shall be provided for all configured alarms including alarms specific to the C&I system.

(10) Alarm response sheets shall be provided in PDF format for the operator.

(11) All alarm response sheets shall comply with the requirements of 240-56355466 - Alarm Management System Guideline.

(12) The Contractor shall implement an alarm philosophy in the C&I system such that:

a. [from VGB R 170 B3e] “Prioritisation and categorisation possibilities of the alarms in at least four stages.”

b. [from VGB R 170 B3e] “Possibility of navigation to allocated process displays per alarm.”

c. [from VGB R 170 B3e] “Alarm lists on visualisation systems with indication of power plant marking system [KKS], alarm text, alarm state (colour distinctions), time stamp (sorted).”

d. [from VGB R 170 B3e] “All signals must be sortable and filterable according to identifier [KKS], priority, time stamp and status and in fact in ascending and descending order.”

Employer’s C&I Interface and Construction Definition Documents

The Employer shall provide design documentation for the Control and Instrumentation engineering design development:

a. C&I Instrument Schedule Template

b. C&I Drive and Actuator Schedule Template

c. C&I Cable Schedule Template

d. C&I Panel Interface List Template

e. Plant Process Description Report Template

f. Control Philosophy Report Template

g. Plant Operating Concept

h. C&I Plant Walk down Observation Report i. C&I Cold Commissioning Report Template

Contractor’s C&I Interface and Construction Definition Documents Design Output Requirements

The Contractor’s design output requirements include the functional requirements, as well as procurement

requirements, quality assurance requirements, construction/installation specifications and instructions, post-

installation testing, post-maintenance testing, and periodic surveillance/testing requirements, including the



“as-designed conditions”. The following are the system design output documents that the Contractor shall

submit for acceptance by the Employer:

i. C&I Instrument Schedule

The Contractor provides the Instrument Schedule for all the instruments forming part of the design and

must be populated in accordance with the Employer’s Instrument schedule template. The instrument

schedule contains all instruments that are connected to the Control & Protection System concerned,

even when the instruments are not provided as part of the Works.

At engineering design freeze the Contractor provides an instrument schedule populated with

the field device data in the following template columns:

Tag name

Tag description (long and short description)

P&ID Reference

Manufacturer

Power Requirements

Power Supply Board

Standard circuit

Power Supply Status Requirement

Thermal protection type

Duty

Starting Time

Type of drive

Integrated Switchgear

Actuator Technical Information

Data Sheet Reference

LOSS

Junction Box (KKS)

ii. C&I Drive and Actuator Schedule

The Contractor provides the Drive and Actuator Schedule for all the drives and actuators forming part

of the design with the Employer’s Drive and Actuator schedule template. The drive & actuator

schedule contains all valves and drives that are connected to the system concerned, even when the

instruments are not provided as part of the Works.

At engineering design freeze the Contractor provides a Drive and Actuator schedule populated with

the field device data in the following template columns:

Tag name

Tag description (long and short description)

Instrument data

P&ID Reference



Process Operating Data

Process Conditions

Inline Devices

Tapping Point Information

LOSS reference.

iii. C&I Cable Schedule

The Contractor provides the cable schedule that lists all instrumentation cables and power cables

which form part of the Works.

The cable schedules shall be inclusive of the origin, location details, revision number, target, type,

size, and termination details of the cable.

iv. C&I Panel Interface List / Hardwired Signal List for External Signal Exchange

The Contractor provides the input information on the Field Hardwired Signal List for External Signal

Exchange that contains all black boxes and panels supplied.

At detail engineering design freeze the list includes signal KKS, long description (is standardised by

the Contractor with rules accepted by the Project manager), short description, etc.…

v. Process Description

The Contractor provides the description of the process design, providing an operational definition of

the major components of the process (also known as a process narrative). The description specifies,

in a complete, precise and verifiable manner, the requirements, design, behaviours or other

characteristics of the process.

vi. Control and Operating philosophies

The Contractor provides an Operating Concept document prepared at the design level that describes

how a particular system (new, modified or existing) will be operated to satisfy its user and operator

requirements. The Operating Concept describes the system operating intent and context.

vii. Field Equipment Design report

The Contractor provides a design report that specifies the field equipment design including the

functional, technical, performance and testing requirements for the design.

viii. P&IDs

The Contractor provides a Piping and Instrumentation Diagram (P&ID) that indicates the process

piping, instrumentation and process control loops; indicating all plant process equipment, valves, in-

line devices and instrumentation to safely operate and protect the plant. It should also indicate tie-in

points, utility interfaces and plant codification information.



ix. Termination Schedule

The Contractor provides a termination schedule that lists all the equipment termination points for all

cabinets, panels, junction boxes and splitter boxes provided.

x. General Arrangement Drawings

The Contractor provides general arrangement drawings that depict all 3rd party black and LCP’s

boxes located in the plant.

xi. Mechanical Hook-ups

The Contractor provides a detailed updated mechanical hook-up drawing per instrument which shows

all of the elements used to mechanically connect an instrument to the plant process.

Typical mechanical hook-ups are provided for each type of application.

xii. Junction Box GA and Internal Layout Drawings

The Contractor provides typical GA and internal layout drawings for junction boxes which define the

design and structure of junction boxes.

The drawings include an equipment schedule for components within the junction box.

xiii. Instrument Stands GA Drawings

The Contractor provides typical instrument stand GA drawings for each type of instrument stand

available for use showing dimensions, structural supports etc.

xiv. Junction Box and Instrument Stand Location Details

The Contractor provides Location drawings showing the location of all junction boxes and instrument

stands on a plant arrangement drawing.

The location detail drawings are produced and grouped by applicable plant area

xv. Alarm List

The Contractor provides an alarm list that lists all the alarms forming part of the plant system.

As a minimum, the following alarm characteristics of the alarms are shown in the alarm list:

a. Alarm KKS.

b. Alarm description.

c. Alarm thresholds and states.

d. Alarm priority.

e. Alarm type

3.2.7. Civil engineering and structural works

The Contractor is required to design and construct all associated civil and structural infrastructure required for the works.

The Contractor provides a detailed design report signed by a Professional Civil Engineer which includes:



Survey drawings, design criteria/parameters, specifications and standards that were used, loadings, assumptions, calculations and results including detailed design calculations, design models, sources of information and any record of other information associated with the completed works. All calculation files and analysis/design models are also submitted in native electronic format together with the design report.

The Contractor provides detailed drawings for construction. Drawings are also submitted in CAD formats (.DGN). All submitted drawings to be signed by a Professional Civil Engineer or Technologist with ECSA registration number stated on drawing. The Contractor is responsible for construction monitoring at the level required to certify that the works have been constructed in accordance with the design.

All civil and structural works required for the project should be done in accordance with the applicable Eskom and SANS standards as listed herein.

Blower Houses, Switchgear and C&I Rooms

The west blower house is located next to smoke stack 4. The east blower house is located inside the hopper units at hoppers units 3 & 4. The buildings are approximately 7m x 5.8m with a height of 4.8m. The blower room portion of the buildings are located on ground level and the switchgear & C&I rooms are suspended 1.15m above ground level with a raised concrete floor creating a cable void for all required cable ways. HVAC support slab & upstand plinths for the exterior units are located next to the building.

The Blower Houses, Switchgear and C&I Rooms were constructed for the project by Others however defects were not rectified and it was not handed over. The buildings were designed to be two hours fire rated, which includes all doors, walls and roofs. Rooms were provided with two escape routes. The buildings were constructed with masonry brick walls supported on a conventional concrete strip footing. All walls were to be face brick finish exterior with interior walls and roofs plastered and painted. All roofs were to be flat concrete roofs. The surface beds, raised concrete floors and cable trenches were constructed with reinforced concrete

The Contractor is required to perform a review, to ensure the construction is as per the design and provide a Completion Certificate signed by a Professional Engineer/Technologist confirming the buildings were constructed in accordance with the design as stipulated in the National Building Regulations and Construction Regulations.

The Contractor also provides as-built drawings signed by a Professional Engineer/Technologist for the buildings.

The Contractor may perform any additional testing, destructive or non-destructive, to determine if construction was in accordance with the design should the information be missing or inconclusive in the data books provided by the Employer. Where destructive tests are conducted, damages are reinstated to the original specification by the Contractor.

The Contractor is required to rectify any defects and commissions the Blower Houses, Switchgear and C&I Rooms.

3.3. Procedure for submission and acceptance of Contractor’s design

The Contractor submits detail design reports and associated drawings for the following:

Process design

Mechanical detail design

Electrical detail design

Control and Instrumentation detail design

Civil detail design The Contractor’s design includes the documents specified in the VDSS. The Contractor’s design includes the modification required for the part of the works already constructed by Others.

Refer to 0 for a description of the documents.

The Employer’s governance procedures require the Employer to perform End-of-Phase design reviews. The Employer requires a period of four (4) weeks for each design review.



3.4. Other requirements of the Contractor’s design

3.4.1. Responsibility for Design

All designs, design reports and Construction drawings prepared by the Contractor are signed off by an ECSA Professionally registered Technologist or Engineer who takes full professional accountability for the designs.

The Contractor is mandated in terms of Construction Regulations 2014: Duties of Designer, 6(1) a - j and 6(2) a – d, to fulfil the duties described therein for the detailed and temporary works designs done by the Contractor. Any risk associated with the Contractor’s design is highlighted to the Employer together with mitigation measures.

The Contractor is responsible for construction monitoring at the level required to certify that the works have been constructed in accordance with the design.

3.4.2. Engineering Documents

For consistency it is important that all documents used within a specific domain follow the same layout, style and formatting standard.

The creation, issuing and control of all Engineering Drawings are in accordance to the latest revision of the Employer’s standard: 240-86973501 (Engineering Drawing Standards – Common Requirements). Micro station is the Eskom standard CAD software.

3.4.3. Plant Coding Allocation

Coding of the design will be based on the KKS coding system and the Employer will undertake the coding in line with Camden P. S. Label Specification and Plant Codification Procedure (240-64550692). The KKS coding shall be applied during the design review stage(s) and cross referenced to all arrangement drawings, schematics, wiring diagrams, instructions and manuals and where practical to spare parts list/manuals. The Contractor will be required to include allocated coding to the electronic design drawings.

3.4.4. Configuration change control

Any changes to the design baselines will be formally managed according to the Employer Project Engineering Change Procedure (240-53114026). All design reviews will be conducted according to the Design Review Procedure (240-53113685)

3.4.5. Site Conditions

The Contractor ensures that the works are designed to accommodate the following ambient conditions such that the operation of Plant and Materials is not impaired, damaged or does not perform according to requirements.

Station datum level : 1 665.12 m.a.m.s.l.

Ambient Temperature : Summer: 13.1 to 24.7 °C.

: Winter: 0 to 16.3 °C.

Rainfall : 724 mm – annual.

: 121 mm – Jan. highest month.

: 190 mm (1:100 year 24 hour storm event).

3.5. Use of Contractor’s design

The Contractor’s design is used to complete the Works. All documentation as specified in this document is supplied to the Employer by the Contractor.



Any detail design drawings required for maintenance purposes is supplied to the Employer, by the Contractor. The detail design drawings or fabrication drawings supplied to the Employer by the Contractor can be supplied to any maintenance partner that the Employer wishes to enter into a partnership with during the life of the Plant. The Contractor notes that all GA, assembly and disassembly drawings become the property of the Employer upon Completion of the Works. The Employer is permitted to purchase replacement parts off these drawings from the lowest cost suppliers.

3.6. Design of Equipment

N/A

3.7. Equipment required to be included in the works

The Contractor is required to furnish and maintain the necessary Equipment for the completion of the Works which includes all: • Manual and power tools. • Rigging. • Vehicles. • Site workshops. • Cranes. • Elevators. • Lifts. • Etc.

• Contractors are expected to mark all their tools, scaffolds, and other temporary Equipment for easy identification. Others are allowed to inspect the shipment of tools and Equipment leaving the site if so requested. A detailed list of tools and Equipment being shipped offsite is required from the Contractor prior to removal from site.

• The Contractor provides all scaffolding required for the completion of the Works.

• The Contractor is not allowed to utilise a tower crane, only mobile cranes are allowed to be utilised. If the Contractor is not able to complete a task without a tower crane this task is brought to the attention of the Employer.

• The Contractor includes a construction execution plan outlining the means and methods they intend to use in executing the Works. The plan includes the proposed position of Equipment required (e.g. crane arrangement) in sufficient detail to determine the viability of the Contractor’s execution plan.

• The Contractor provides all test Equipment for testing the individual modules, the sub-assemblies and the functional groups for site testing and commissioning.

3.8. As-built drawings, operating manuals and maintenance schedules

The Contractor provides the following three weeks before commissioning:

• As-built revision of all the design documents;

• Operating and maintenance manuals.

• Certificate of Compliance issued in terms of SANS 10142-1

The Contractor submits the following documentation for acceptance before the Completion of the whole works:

• Commissioning data books;

• Updated As-built documentation where required.



All as-built documentation and databooks are signed by the Contractor’s Professional Engineer/Technologist.



4. Procurement

4.1. People

4.1.1. Minimum requirements of people employed on the Site The detailed project organisational structure, accompanied by CV’s of key personnel, is accepted by the parties at the Contract Date. The Contractor shall provide for professional registered (Pr.Eng) and experienced design engineers. The engineers will have minimum of six years related experience.

4.1.2. Drawing Office Staff Drawing office facilities are available in or around South Africa after System Engineering design freeze, and they are competent to supply the following services:

• Modification and revision of overseas generated drawings. • Production of new drawings as required.

4.1.3. QA Staff

The Contractor provides suitably qualified staff with proven professional experience in developing and maintaining QA and QC measures for the duration of the contract in accordance with Section 2.6. The Contractor provides an organogram of the employed staff as well as a CV for each staff member.

4.1.4. Training Personnel The Contractor supplies suitably qualified and experienced staff for the purposes of formal training. As specified in Section 2.6.

4.1.5. Key Site Personnel

The Contractor provides sufficient personnel with the required experience, expertise and skills to provide the effective execution of the Works. Details of the Contractor’s manpower on Site are submitted together with the proposed execution programme. An approved organogram of head office and site personnel to be submitted to the Employer. The Employer considers the provision of sufficient Supervisory staff to be an essential part of the responsibilities of the Contractor and requires the Contractor to appoint a suitably qualified representative to permanently manage all aspects of the Contractor’s activities and responsibilities on site for the duration of the contract.

4.1.6. Legal appointments All staff that is appointed to work by the Contractor should have a legal binding contract with the personnel or HR Department to manage them. All personnel appointed should provide a valid Curriculum Vitae (CV) to keep on record on the site works as well. Personnel must be available for PSR training if needed before the works start.

4.2. Supplier Development Localisation & Industrialisation (SDL&I)

4.2.1. Localization

Tender submissions will be accepted from the following entities ONLY:

Tenderer(s) with B-BBEE level 1 – 4 contributors who commit to subcontract a minimum 30% of contracted value to designated groups as stated on Preferential Procurement Regulations, 2017;



Tenderers should have a CIDB contractor grading designation of 7ME or higher, 6ME potentially emerging enterprises who satisfy criteria stated in the Tender Data may submit tender offers.

Joint Venture (JV) parties must comply with the CIDB Regulation 25(5)(a) which states:

(5) Subject to sub-regulation (1), joint ventures are eligible to submit tender offers or expressions of interest

if- (a) Every member of the joint venture is a registered contractor in terms of these Regulations and the lead

partner has a contractor grading designation of not lower than one level below the required grading designation in the class of construction works under consideration and possesses the required recognition status.

4.2.2. Skills Development

The Contractor shall develop a committed number of candidates for skills development. These candidates shall be sourced from Gert Sibande District Municipality in Mpumalanga Province (i.e. where the actual production will be taking place) as shown in the SD&L Compliance Matrix below. The purpose is to provide these candidates with skills and workplace experience in order to increase the opportunity for them to be employable within the industry. The Contractor may develop the candidates directly, through their supply network or through the SETA accredited training providers.

Contractor is encouraged to propose against the following training initiatives:

Category Eskom Target

Tenderer Proposal

Pipe Fitter 2

Scaffold Erector 2

Safety Officer (SAMTRAC)

1

Skills development candidates should be unemployed graduates from TVET Colleges and disadvantaged universities and/or matriculates. The composition of the candidates shall be representative of the demographics of South Africa.

A detailed training plan with milestones as to when the training will commence and be completed will be required from the Contractor, 30 days after the contract award. This programme will be monitored and audited as per the agreement between the Contractor and SD&L Monitoring and Reporting team.

4.2.3. Skills Development reporting:

With regard to skills development, the same student cannot be linked to more than one project at the same time. The Contractor will be required to provide Names, Identification and Contact numbers, as well as certified copies of Identification documentation of students on skills development which will be monitored within Eskom.

4.2.4. Job Creation

No of Jobs to be created No of jobs to be retained

10

4.2.5. SD & L Reporting

Local Content progress reporting to be done on a monthly basis by the 5th of each month

4.2.6. SD & L Penalty The penalty for failure to meet the SD&L commitments 2% of the total of the Prices as at the Contract Date.



Attendance on subcontractors

• N/A

4.2.7. Plant & Materials provided “free issue” by the Employer

N/A

4.2.8. Contractor’s procurement of Plant and Materials

The Contractor procures, obtains necessary permits, stores and transports to Site any Plant and Materials needed for provision of the works. The Employer does not provide any storage place except for the Contractor’s laydown areas. The Contractor may request temporary storage place from the Project Manager. The Project Manager observes the Contractors request for temporary storage place and if available grants it.

4.2.9. Spares and consumables

Replacement components are to be readily available. The Contractor guarantees that the all components are available in South Africa in the foreseeable future for at least 20 years.

4.3. Tests and inspections before delivery

Vibration tests according to BS ISO 10816

4.4. Marking Plant and Materials outside the Working Areas

N/A

4.5. Contractor’s Equipment (including temporary works).

N/A

4.6. Cataloguing requirements by the Contractor

N/A



5. Construction

5.1. Temporary works, Site services & construction constraints

The Contractor is responsible for the construction of all temporary works required for the execution of the works and is mandated in terms of Construction Regulations 2014: Duties of Designer, 6(2) a – d, to fulfil the duties described therein for the temporary works designs done by the Contractor. The Contractor’s appointed ECSA professionally registered engineer:

Reviews and approves (by signature) the designs and drawings of all temporary works and additional supports and method statements produced by the Contractor; and

Supervises, inspects and approves the works as per such.

All temporary works designs, where existing infrastructure are impacted by the works, are submitted to the Project Manager for review and acceptance, to prove that the existing infrastructure can withstand the induced load. The Contractor therefore submits all design calculations, in a design report which includes, but is not limited to, all inspection reports, survey data, design analysis models, assumptions, drawings/sketches, rigging studies etc.

5.1.1. Employer’s Site entry and security control, permits, and Site regulations

The Contractor takes note that Camden Power Station is a National Key Point and therefore, site access requirements need to be adhered to. This is inclusive but necessarily to access approval, safety induction and medical examinations. The Contractor abides by all National Legislation, Eskom regulations and procedures and Camden Site procedures and instructions.

5.1.2. Restrictions to access on Site, roads, walkways and barricades

The Contractor abides by all National Legislation, Eskom regulations and procedures and Camden Site procedures and instructions.

5.1.3. People restrictions on Site; hours of work, conduct and records

The Contractor abides by all National Legislation, Eskom regulations and procedures and Camden Site procedures and instructions.

5.1.4. Health and safety facilities on Site The Employer has medical centre on Site to provide first line health care in case of any unforeseen injuries that may occur. The Contractor is responsible of providing medical health certificates for all of his employees before access to Site in line with National Legislation, Eskom regulations and procedures and Camden Site procedures and instructions.

5.1.5. Environmental controls, fauna & flora, dealing with objects of historical interest The Contractor abides by all National Legislation, Eskom regulations and procedures and Camden Site procedures and instructions.

5.1.6. Title to materials from demolition and excavation

All Materials removed from the plant remains the Employer’s property. The Contractor is however responsible for transporting the Material to the correct laydown area and/or correct disposal facility.

5.1.7. Cooperating with and obtaining acceptance of Others



The specific area may be shared with a number of other Contractor’s performing other work. The Contractor co-operates with other Contractor’s to ensure safety, proper work planning and streamlining of activities to complete the work in a cost effective manner, to the required quality and according to the approved programs.

5.1.8. Publicity and progress photographs

The Contractor is not allowed to take any photographs on Site, unless written permission was received from the Project Manager.

5.1.9. Contractor’s Equipment

All equipment shall conform to acceptable standards and safety standard and comes with the required certification where required (Load test certificates, COCs, etc.).

5.1.10. Equipment provided by the Employer

None

5.1.11. Site services and facilities

The Camden Site is to be considered as operational at all times and is the responsibility of the Contractor to locate and protect all existing services and infrastructure such as electrical cables, water, sewer, storm water, power lines, gas lines, airlines, pipelines, etc. from damage during the execution of this Contract. The Contractor is responsible for repairing and re-instating any damages. The Employer provides water, sanitation and electricity for Site offices but it remains the responsibility of the Contractor to tie into the local infrastructure and remove such tie-ins on completion of the Contract.

5.1.12. Facilities provided by the Contractor All services and facilities that are not specifically stated to be provided by the Employer and which are necessary for providing the Works are provided by the Contractor.

5.1.13. Existing premises, inspection of adjoining properties and checking work of Others

N/A

5.1.14. Survey control and setting out of the works

The Contractor is responsible for setting out the works as shown on the drawings.

5.1.15. Excavations and associated water control

All necessary precautions shall be taken to ensure that deep excavations are safe and that the sides are stable, if not they shall be battered. All excavations are to be properly barricaded at all times

5.1.16. Underground services, other existing services, cable and pipe trenches and covers

The Camden Site is to be considered as operational at all times and is the responsibility of the Contractor to locate and protect all existing services and infrastructure such as electrical cables, water, sewer, storm water, power lines, gas lines, airlines, pipelines, etc. from damage during the execution of this Contract.



The Contractor is responsible for repairing and re-instating any damages.

5.1.17. Control of noise, dust, water and waste

The Contractor controls noise, dust, hazardous materials and waste as required by National Legislation, Eskom regulations and procedures and Camden Site procedures and instructions, whichever is considered to be the most restrictive and safe in the opinion of the Project Manager.

5.1.18. Sequences of construction or installation

Any modification to the existing hoppers can only be done while the hopper is not in operation. The fabric filter plant is divided in cells which can be isolated individually while the rest of the plant is still in operation. The Contractor performs all the work on a specific cell at the same time to minimise the impact on the operations of the plant.

5.1.19. Giving notice of work to be covered up The Contractor is to give the Supervisor at least three (3) day notice before covering up the work.

5.1.20. Hook ups to existing works

The Contractor obtains written permission from the Project Manager to hook up to existing works before proceeding with such activities.

5.2. Data Books

The Contractor compiles data books progressively for all manufacturing and construction/erection inspection, operating manuals and test records and documents for every piece of plant worked on. The Contractor submits data books to the Supervisor and Project Manager for their review for all equipment and works undertaken with the applicable requirements and specifications.

Apart from any statutory data packages required, the Contractor also compiles and signs off a data package of the relevant drawings, test certificates etc. to the Project Manager for acceptance. These include, but are not limited to:

Geotechnical Investigations

Surveys

Approved ITP’s, QCP’s;

Method statements and specifications adhered to;

Rigging studies;

Risk assessments;

Approved Drawings;

Design Calculation Reports

Fabrication Drawings;

Material Certificates;

Weld Map;

Weld Matrix Sheet;

Weld Sequence;

Welding Consumables Certificates;

Welding Procedure;

Welders’ Qualifications;

ESKOM approved NDT Contractor;

Approved NDT procedure;

NDT Technician Qualifications;

NDT Reports/ Results;



Certificate of Manufacture;

Inspection Reports;

Corrosion Protection Consumables Certificates;

Calibration Certificates;

Notifications;

Modifications;

Concessions;

5.3. Completion, testing, commissioning and correction of Defects

Technical Queries, Engineering Responses and communications with Project Manager/

Employer

Non-conformance reports;

Internal Release Notes;

Transport notifications;

Calculations for any temporary works that may be required for the safe execution of the works;

Concrete 7 day and 28 day cube test results;

Slump test results;

Concrete mix designs including all required test results e.g. aggregate test results;

Pre-concrete and post concrete surveys;

Batch Plant certificates;

Slump tests certificates;

Compaction tests;

Material certificates;

As-built data and drawings of the completed works.

Professional Engineering Certificates confirming that construction of the works designed by the Contractor as well as works constructed by Others is in accordance with the design.

Currently the employer has partially complete data books for the works that have already been constructed by Others, which will be provided to the contractor.

5.3.1. Work to be done by the Completion Date

On or before Completion the Contractor shall have done everything required to provide the works.

5.3.2. Use of the works before Completion has been certified

• The hot or cold commissioning period commences when a safety clearance certificate has been

issued for a particular piece of machinery by the Employer. • During the commissioning period, the Employer being the 'User' has the right of control over the

use of the machinery in terms of the OHS Act. • The Employer is responsible for the control and operating of plant safety regulations and

operating regulations for high voltage systems. • The Employer refuses to operate any piece of machinery that it considers 'not to be safe' or

detrimental to the machinery/system when operated. • The Contractor provides the necessary expertise and the resources for commissioning of the

machinery. • In the event of incorrect functioning, the Contractor determines the cause of the fault and he

corrects the fault if the trouble is within equipment of his own supply, or notifies the Project Manager who will instruct Others to rectify faults within their equipment.

• The Contractor carries out any required routine maintenance on machinery until a Completion Certificate has been issued. The Contractor supplies all the required spares during this period.

• The Contractor requests, through the Project Manager, that the power station carry out routine maintenance on the Contractor’s behalf, after the machinery has been taken over. This request is to be in writing and supported by adequate instructional details.



• The Contractor presents the completed works to the Project Manager for a complete inspection, after being successfully commissioned. The Contractor carries out repairs on all Defects, in those portions of the work that the scope of work covered, detected during that inspection.

5.3.3. Materials facilities and samples for tests and inspections

The works will be comprehensively inspected and tested at the factory by the Supervisor, prior to shipment. The Supervisor reserves the right to appoint a representative or representatives to inspect all parts during manufacture, and erection and to be present at any of the tests specified. Such witnessing of tests by the Supervisor does not relieve the Contractor of his responsibilities if the Supervisor chooses to waiver in writing the witnessing of any tests. The Contractor provides all test equipment for any inspections and tests. Such tests as may be required by the Employer shall be carried out by the Contractor after erection to prove compliance with the specification independently of any test, which may have been carried out at the manufacturer's factory site. All such inspection and testing activities will be documented as per the ITP/QCP.

5.3.4. Commissioning

Commissioning is defined as bringing into service all Plant and meeting the functional requirements and performance criteria as specified in the works. The Contractor is responsible for co-ordinating and executing commissioning activities in conjunction with the various departments of the Employer namely Operations, Engineering, Commissioning and QA/QC as well as Others that have interfaces with the Plant. Commissioning includes testing and verification of the stated performance criteria with:

Minimum Testing and Assessment criteria (as set-out, but not limited to, this works document as well as supplementary requirements which will be discussed with the detailed QA/QC plan).

Requirements and detailed engineering design review and design freeze process (240-53113685, Rev1).

Commissioning of the Plant commences after the plant safety clearance (which includes submissions such as the Contractor’s Mechanical Completion Certificate to the Project Manager) and the Site Integration Tests have been completed and accepted. The Contractor prepares and submits, three (3) months before the commissioning phase commences, for acceptance to the Project Manager, Commissioning and Testing Procedures for all the commissioning and testing activities to be performed, detailing the methods, functionality checks, and acceptance criteria thatare applicable. The accepted schedule forms the basis of the commissioning and testing program that is implemented during the overall unit commissioning and testing program.The Contractor commissions the works including the parts of the works constructed by Others. The Commissioning and Testing Procedures includes but is not limited to:

System completeness checks (including visual inspections)

Instrument calibrations

Loop checks

Pre-energisation checks

Information acceptance testing

Simulator acceptance tests

System internal cleaning

System set up

System function checks

Hot commissioning including system check procedures

Noise tests

All commissioning check sheets and tests

Operational Acceptance Test reports

Permits and Safety Any commissioning and testing activity is confirmed on the project schedule with the Employer and if necessary, rescheduled requested, in writing) by the Contractor in the appropriate forum provided it is (forty eight) 48 hours in advance to allow for the release of the plant for operation. The Contractor interfaces directly with the Employers’ commissioning staff and Others and is available on a twenty four (24)-hour basis if required for specific activities until the Commissioning phase is completed.



The Contractor visually inspect the Plant and components to verify the placing of plant labels for their correctness and completion as per the requirements as specified in the works, which is also captured in the ITP/QCP and data book documentation. The Contractor provides sufficient skilled personnel for the satisfactory and timely commissioning of Plant; including the re-commissioning of existing equipment that forms part of the works. The Contractor provides all the test equipment for commissioning. Any Defects identified during the commissioning process are corrected by the Contractor. Once all Defects are corrected the commissioning process is restarted. The Contractor certifies, in writing and in an official format (Certificate of Manufacture), to the Employer that Plant is in a suitable and safe condition for use before it is placed in service. The Contractor submits to the Project Manager for acceptance and endorsement in the ITP/QCP and documented in the data book the following documents:

All commissioning check sheets and tests

Operational Acceptance Test reports

Permits and Safety During the commissioning phase tests are conducted by the Contractor, with the results submitted to the Project Manager, on all modified items and silencers to confirm that all plant meets the OHS Act requirement. This is done by suitable qualified personnel.

5.3.5. Start-up procedures required to put the works into operation

The Contractor gives the Project Manager written notice that the Plant is ready to be put in operation. Such notice suits the requirements of the Employer and is not, unless otherwise agreed, less than 48 hours or more than fourteen (14) calendar days. No alterations or adjustments are made to the Plant after functional checks are done without the Project Manager written permission. At this stage the following must have been achieved:

Installation and pre-commissioning completed.

Testing report and the associated certificates received.

Signed erection and safety clearance certificates.

Final Draft of the Technical, Operating, Maintenance manuals delivered.

All Quality Control Plan (QCP) documentation received.

All design reviews as required by the Employer conducted and approved.

5.3.6. Take over procedures

Commissioning is concluded with the Operational Acceptance Test (OAT). The Contractor requests commencement of operational acceptance test from the Supervisor and is recorded on a ITP/QCP and documented in the data book. The Contractor produces a detailed operational acceptance test procedure twenty (20) working days in advance for acceptance by the Project Manager. This is shown on the Accepted Program. As a minimum, the OAT procedure includes the loop tuning procedures and acceptance criteria for the individual loops. The work is pre-tuned in order to prevent deviation limits of process parameters from exceeding the maximum permissible values defined during the detailed engineering phase. After satisfactory completion of installation and commissioning of the control system in conjunction with the plant, the Contractor demonstrates that the control system successfully performs the following:

Plant operated local and/or remotely manually.

Plant operated on manual with all remote Supervisory/monitoring functions in the main control room.

Plant operated automatically (start-up, sequential control and shutdown) with all remote Supervisory/monitoring functions.

Plant operating on modulating control, responding to a safe and stable state for dynamic changes in the plant.



All individual operating and control functions such as alarms, displays, report generation, historian views, perform successfully.

Process server and Station plant information system functions are demonstrated, including process LAN and client access operations according to the works Information and all archiving and back-up functions.

The final OAT Report is prepared by the Contractor. The Contractor submits the final OAT Report to the Project Manager for acceptance. Commissioning Completion is achieved upon acceptance of the OAT Report by the Project Manager. The works is not deemed to be in completed until the Completion Date. The works is taken over on that date and the Defects period runs from that date. Takeover by the Project Manager is dependent on successful completion of the works, commissioning and testing, works labelling and all required documentation handed over and all known Defects corrected. The Contractor is still liable for the completion of the information test A and the success of acceptance test B after takeover.

5.3.7. Access given by the Employer for correction of Defects

If Defects on the Plant are detected after the Completion of the works and the Plant has been handed over to the Employer, it is the Contractors responsibility to correct the Defect. The Contractor supplies the Project Manager with a plan to correct the Defect within the time specified in the Contract Data.

5.3.8. Performance tests after Completion

After Completion of the Works the Contractor applies formally to the Employer to conduct any tests on the Plant. No optimisation and commissioning of the Plant is permitted during any testing periods. The Contractor develops and submits for approval to the Employer a complete testing and inspection procedure for all tests/test phases to be conducted after Completion of the works. The testing and inspection procedure includes all tests and inspections deemed necessary by the Contractor to prove to the Employer’s satisfaction that the Plant performs according to the Employers specification. The testing and inspection procedure includes as a minimum:

Correct switching of the level switches.

Confirmation that the hopper aeration allows the ash to flow freely. In the case of a failure of any of the tests/test phases, the functional tests for the relevant areas of the Plant and all affected areas of the Plant are repeated. The capacity and reliability tests are redone in total on the relevant Plant. During the test period, the Employer’s personnel operates the Plant, under the supervision of the Contractor. The Contractor is not permitted to directly operate the Plant. The Employer reserves the right to carry out further testing on the Plant. On completion of all the tests the Contractor supplies in triplicate, completed test certificates. The Contractor supplies all prescribed statutory documents as are required, certifying that the Plant is in complete working order and that all working parts are evenly lubricated.

5.3.9. Training and technology transfer

Training courses for the Employer’s Engineering, Maintenance and Operating personnel are provided by the Contractor to ensure that the Employers personnel are fully conversant in operating, testing, fault finding and maintaining the new systems. The training program is developed by the Contractor and accepted by the Project Manager. The training includes but it not limited to the following:

The Contractor provides training on the Plant included as part of the works to the various categories of the Employer’s technical staff for the duration of the project.

All training is local, provided by the Contractor, and customised for Camden P.S. and is directly applicable to the actual equipment supplied for the works.

Training is focused on the specific systems’ architecture, configuration, layout, equipment and design that the Contractor provides.

Training facilities are provided by the Contractor.



Training material and tools are not shared by trainees during the training.

The training facilities provided are: o Accommodates all trainees comfortably o Includes all engineering tools and workstations o The training is provided as per the detailed training programme and prospectus accepted by

the Project Manager o Classroom and practical hands-on training were required is provided to the Employer’s

personnel.

5.3.10. Operational maintenance after Completion

N/A

5.3.11. Survey control and setting out of the works

1. The Contractor is responsible for the complete surveying and setting out of the works including establishment and protection of any benchmarks required to complete the works.

2. The Contractor is required to consult the Surveyor-General’s office to obtain information on available registered beacons near Camden Power Station to use for the establishment of any required benchmarks close to the works.

3. The Contractor is responsible for conducting all surveys required for the detailed design of the works. The level of detail of the survey conducted is as required for the detailed design.

4. All surveys are done using the WGS 84 LO29 coordinate system and are in accordance with TMH 11.

5.3.12. Excavations and associated water control

1. The Contractor is responsible for all risks and costs associated with water, whether from a local water course, an underground spring or any other source or cause.

2. The Contractor takes all precautions and properly deal with and dispose of all water to ensure that:

The works are kept sufficiently dry at all times for their proper execution;

There is minimum deleterious impact on the environment and adjacent properties; and

There is minimum damage, inconvenience or interference arising from flood waters. 3. The Contractor is responsible for the construction of sumps, furrows, drains, oil separators, slurry trenches, cut-off trenches and any other temporary works as may be necessary to deal with water.

4. The Contractor provides, operates and maintains in sufficient quantity such pumping equipment, well points, pipes and other equipment as may be necessary.

5. Surface works and excavations are protected against the ingress of surface water and the Contractor takes whatever precautions may be required.

6. The Contractor takes all necessary steps to ensure that any water entering any surface excavation does not endanger the stability of the surface excavation, or that water entering such surface excavation does not erode any portion of the excavation.

7. The Contractor ensures that no concentration or accumulation of water occurs either within or around or above the area of any open excavation which may affect the safety of the excavation.

8. The Contractor, where possible, maintains excavations such that ponding of rain water is prevented by suitably sloping surfaces and the construction of channels and sumps.

9. Where excavations are not self-draining, the Contractor constructs sumps and installs pumps of adequate capacity to keep the water level in such sumps 0.5 m below the lowest excavated surfaces for as long as required for construction of the works. Diesel powered standby pumps are readily available in case of breakdowns.



10. The Contractor is responsible for the safety and care of the excavations as stipulated in Construction Regulations, 2014.

5.4. Waste Management

1. Materials such as excess silt and water will be adequately disposed of with minimum impact to the

environment.

2. All demolition wastes are required to be disposed in a licenced disposal facility accepted by the

Employer.

3. The waste disposal site is selected to suit the classification of the materials to be disposed of.

Certificates of disposal are required to be submitted to the Employer.

4. The waste management procedure for Camden power station is required to be complied with.

5. The Contractor continuously monitors the condition in demolition areas and surrounding areas for

any hazardous substances and in such case, the Contractor is required to take necessary

precautionary measures.

The Contractor is to give the Supervisor at least three (3) day notice before covering up the work.

5.5. Requirements during work

Included in the Contractor’s requirements are but not limited to:

1. Construction and erection, painting and finishing, installation, commissioning, testing, training,

optimisation and handover of Works and Materials for a fully operational and functional

Infrastructure, non withstanding and not limited to the scope in the Works.

2. Design, installation and removal of any temporary works required for the execution of the works.

3. Integration and phasing with other projects executed by Others.

4. Integrates the infrastructure with the existing power station systems and liaises with the original

suppliers of the related plant to ensure the compatibility of operation of the existing systems with

Plant.

5. Provides technical oversight during construction.

6. Provides all Equipment (including scaffolding and crainage) requirements for construction.

7. Provides a method statement for the construction and sequencing of the work subject to the

approval of the Project Manager.

8. All inspection/quality reports, construction records, commissioning test reports, and other

documentation as required by the Works.

9. Dismantling, decommissioning and removal of all associated redundant equipment

5.6. Fabrication and Construction

The works to be provided by the Contractor include:



1. Provision of all scaffolding, site craneage, lifting equipment, etc. which are required by the

Contractor.

2. All excavations required and casting of all collection points.

3. Provision for all signage

4. Construction of all earthworks and terracing required.

5. Any modifications required for the use of existing structures or slabs.

6. Construction of the works. Provision is also made for temporary road crossings during the

construction of the permanent crossing to ensure access to all required areas.

7. The Contractor provides details of any propriety products that are proposed to be used for

acceptance by the Project Manager.

General

The Contractor:

1. Adheres to the South African Environment Protection Act, the waste management code of practice

and the South African Occupational Health and Safety Act No. 85 of 1993, the regulations

promulgated thereunder and Eskom Safety, Health, Environment and Quality (SHEQ) Policy 32-727

for all works.

2. Submits a comprehensive method statement of the entire works to the Project Manager for

acceptance prior to the start of the works

3. Submits a project specific safety file to the Employer for comments / acceptance.

4. Submits a detailed level 3 schedule for the works to the Project Manager for acceptance after contract

award.

5. Takes all necessary precautions to ensure that none of the existing structures / facilities not forming

part of the works is damaged during construction.

6. Prepares earthworks to create access to the working areas. The Contractor disposes of all rubble at a

waste disposal site to be approved by the Employer. The waste disposal site is selected to suit the

classification of the materials to be disposed of. Certificates of disposal are required to be submitted

to the Employer.

7. Stores salvaged plant/materials/components elevated off the ground to protect from ingress of dust

and rainwater, etc.

8. Continuously monitors the conditions within the working and surrounding areas for any hazardous

substances or situations, and in such case, the Contractor are required to take necessary

precautionary measures.

9. Manages his access to the working areas and the Site.

10. Manages his activities on Site to ensure that no interference takes place between his work and that

of others.

11. Completes "Contract Activities Daily Reports".

12. Liaises with the Supervisor regarding utilities and telephone facilities required for his Site

establishment.

13. Liaises with the Supervisor regarding the location of waste disposal sites and rubbish dumps.



Construction and Erection

1. The Contractor takes full professional accountability and liability for all temporary items required for

the execution of the works.

2. The Contractor submits a comprehensive method statement of the works to the Employer for

acceptance prior to the commencement of the works.

3. The Contractor removes all temporary structures required for the execution of the works.

Completion, testing, commissioning and correction of Defects

Work to be done by the Completion Date

On or before the Completion Date the Contractor shall have done everything required to Provide the Works except for the work listed below which may be done after the Completion Date but in any case before the dates stated. The Project Manager cannot certify Completion until all the work except that listed below has been done and is also free of Defects which would have, in his opinion, prevented the Employer from using the works and Others from doing their work.

Item of work To be completed by

As built drawings of Within days after Completion

Performance testing of the works in use as specified in paragraph of this Works Information.

See performance testing requirements.

6. Plant and Materials standards and workmanship

6.1. General

The works complies with:

240-106628253, Standard for Welding Requirements on Eskom Plant

240-83539994, Standard for Non-Destructive Testing (NDT) on Eskom Plant.

240-54937450, Fire Protection & Life Safety Design Standard Potable water system

The Contractor investigates the location of the existing potable water pipeline to the existing contractor’s camp.

The investigation is done in the proximity of the existing contractor’s camp.

Once the pipeline is located the Contractor investigates the line for a tap of point for the potable water line to the proposed contractor’s camp area.

When the tap of point is found the Contractor presents the finding, in a memo, to the Project Manager for acceptance.

6.2. Investigation, survey and Site clearance

The Contractor is required to conduct geotechnical investigations for all areas required. The geotechnical investigation works will include as a minimum:



1. Geophysical survey to ensure that no underground services are impacted during the geotechnical investigation as well as during construction.

2. Intrusive geotechnical investigation works by means of trial pits and dynamic probe super heavy tests to determine geotechnical input parameters required for design.

3. Soil laboratory testing to determine soil parameters required for civil engineering design of structures and layer-works.

Special attention must be paid to the quality of the materials for usability on site in construction works.

The Contractor must make use of SANAS accredited laboratories. All geotechnical investigations and geotechnical reporting must be conducted by a professionally registered engineering geologist or geotechnical engineer.

6.3. Building works

N/A

6.4. Civil engineering and structural works


SANS 10400 The Application of the National Building Regulations

240-56364545 Structural Design and Engineering Standard

240-85549846 Standard for Design of Drainage and Sewerage Infrastructure

240-84418186 Road Specification Manual

240-56364535 Architectural Design and Green Building Compliance Manual

SANS 2001-BE1 Construction works Part BE1: Earthworks (general)

SANS 2001-BS1 Construction works Part BS1: Site clearance

SANS 2001-CC1 Construction works Part CC1: Concrete works (structural)

SANS 2001-CM1 Construction works Part CM1: Masonry walling

SANS 2001-CM2 Construction works Part CM2: Strip footings, pad footings and slab-on-the-ground

foundations for masonry walling

SANS 2001-CS1 Construction works Part CS1: Structural steelwork

SANS 2001-CT2 Construction works Part CT2: Structural timberwork (roofing)

SANS 2001-DP1 Construction works Part DP1: Earthworks for buried pipelines and prefabricated

culverts

SANS 2001-DP2 Construction works Part DP2: Medium pressure pipelines

SANS 2001-DP3 Construction works Part DP3: Cable ducts

SANS 2001-DP4 Construction works Part DP4: Sewers

SANS 2001-DP5 Construction works Part DP5: Stormwater drainage

SANS 2001-DP6 Construction works Part DP6: Below-ground water installations

SANS 2001-DP8 Construction works Part DP8: Pipe jacking

SANS 2001-EM1 Construction works Part EM1: Cement plaster

SANS 1200 Series Standardized specification for civil engineering construction



SANS 10120 Series Code of practice for use with standardized specifications for civil engineering

construction and contract documents

6.4.1. Additional Requirements and Specifications

1. The Contractor is required to confirm all site dimensions, levels and cast-in items positions on site

prior to any fabrication of steel or casting of concrete.

2. The Contractor is required to submit a comprehensive method statement of the works to the Project

Manager for acceptance prior to the start of the works

3. The Contractor is responsible for the design, erection, maintenance and removal of all temporary

bracing or propping required for the execution of the works.

6.4.2. Concrete

1. All concrete work is required to be in accordance with SANS 2001-CC1 and SANS 10100-2 unless

otherwise stated.

2. All concrete surfaces and cast-in items is required to be inspected and accepted by the Project

Manager in writing before casting of concrete may commence.

3. The Contractor is required to obtain written acceptance from the Project Manager for the use of any

admixture or the use of ready mixed concrete, to pump concrete, or to use cement or cement blends

other than ordinary Portland cement (OPC)

4. Compaction of concrete is required to be done by means of mechanical vibrators only.

5. The Contractor is required to submit the concrete mix design to the Project Manager for acceptance.

6. The Contractor is required to demonstrate, by means of a report from an approved laboratory, that

the aggregates do not exhibit excessive shrinking properties in accordance with SANS 1083 and is

also required to demonstrate that the aggregates do not have a potential alkali silica reaction.

7. The Contractor is required to perform a slump test on the same batch of concrete every time a

sample is taken and the result recorded.

8. Concrete may be produced from an onsite batching plant or, if available, from a local ready mix

plant. Concrete is placed promptly after batching.

9. Sampling of concrete test cubes and slump tests shall take place at the point of deposition.

10. All exposed corners to be chamfered 20x20mm. Jointing design and material are suitable for the

generally high/low temperature conditions on site, to minimize shrinkage and joint failure.

The table below indicates particular specifications pertaining to SANS 2001-CC1 and must be read in conjunction with the code.

Clause Particular Specification

3.5 Concrete – Strength characteristics




3.4.3

Concrete Grade is required to be:

Class 15 MPa/ 19 mm for Blinding Concrete (28 days),

Class 35 MPa/ 19 mm for Structural Concrete (28 days).

4.2 Materials

4.2.7

In general, one of the following types of non-shrink grout are

required to be used:

Cement-based non-shrink grout, not less than 50 MPa;

Special proprietary non-shrink or expansive grout, not less

than 50 MPa.

4.4 Reinforcement

4.4

Add the following:

All reinforcement is stamped with a SANS quality

assurance mark

4.4.3.1 Cast in-situ concrete cover is required to be a minimum of:

50 mm for all faces

4.7 Quality of Concrete

4.7.1.1

Contractor submits to the Supervisor full details and

samples of all materials which he proposes to use for

making concrete at least 28 days before the concreting of

the works is due to commence.

4.7.10

Add the following:

A layer of blinding concrete of 50 mm minimum thickness

is required to be placed under foundations.

A polyethylene sheet with a minimum thickness of 250

microns is required under ground slabs

4.7.12.2.3 All angled corners are chamfered 20 mm x 20 mm, unless

such other larger size is detailed on the Drawings.

4.7.19.3 Contractor submits a detailed procedure for acceptance

by the Supervisor on how he intends to carry out the

repairs of structural concrete defects

4.7.22

For concrete pour records, the Contractor submits a

detailed Quality Control Plan to the Supervisor for

acceptance.

In addition the Contractor supplies the Supervisor with two

copies of these records each day covering works carried




out the preceding day.

5.1 Testing

5.1.1.4

Six 150 mm cube samples taken from each batch or place

of concrete deposition, three cubes are tested at 7 days

and three at 28 days.

Strength at 7 days is required to be at least two thirds of

28 day strength.

5.1.2.1 Any of the cube samples tested indicating a result more

than 3 MPa below the specified strength is disregarded.

5.2 Tolerances

5.2.1

Tolerances on all concrete work is required to be a level II

degree of accuracy as specified in SANS 2001-CC1 with

and is to be carefully maintained throughout the

construction.

6.4.3. Structural Steelwork

1. All work is required to be in accordance with the latest edition of SANS 2001-CS1

2. The Contractor is responsible for the stability of the entire structure and all structural elements during

all the erection stages.

3. All dimensions are required to be verified on site by the Contractor before any fabrication of

steelwork commences.

4. All welding is required to be conducted by coded welders. Supporting documentation is also required

to be submitted to the Project Manager for acceptance. All welding is required to comply with AWS

D1.1.

5. All welds are required to be inspected using visual aids

6. The Contractor is required to supply all bolts, washers, nuts etc. for the structural steelwork.

7. All steelwork and fencing mesh is required to be hot dipped galvanised.

8. All galvanising is required be done in accordance with SANS 121. Preparation of steel prior to

galvanising and coating thickness is also required to be in accordance with SANS 121.

The table below indicates particular specifications pertaining to SANS 2001-CS1 and must be read in

conjunction with the code.


4.1 Materials




4.1.1 Add the following:

All structural steelwork is required to be grade S355JR

4.1.4.1 Electrodes for electric welding are required to be E7018.

4.6 Workmanship - Erection

4.6.5 On site welding is not permitted

5.3 Non-destructive testing of welds

5.3.3 Fillet welds are required to undergo magnetic particle

inspection (20 % of welds)

5.3.4 All butt welds and full penetration welds are required to

undergo ultrasonic non-destructive testing (100 % of

welds)

6.4.4. Corrosion protection

1. Corrosion protection is required for all structural steelwork in accordance with with 240-106365693: Standard for the External Corrosion Protection of Plant, Equipment and Associated Piping with Coatings.

6.5. Mechanical engineering works

6.5.1. General Requirements


240-101712128, Standard for the Internal Corrosion Protection of Water Systems, Chemical Tanks and Vessels and Associated Piping with Linings

240-102547991, General Technical Specification for HVAC Systems Standard

240-105020315, Standard for Low Pressure Valves

240-105929225, Compressed Air System Standard

240-106365693, Standard for the External Corrosion Protection of Plant, Equipment and Associated Piping with Coatings

240-123801640, Standard for Low Pressure Pipelines

240-56247004, Thermal Insulation Standard

240-89147446, Instrument Piping for Fossil, Hydro, Renewable and Aero-Derivative Power Plants Standard

SANS 2001-CS1, Construction works Part CS1: Structural steelwork

SANS 2001-DP2, Construction works Part DP2: Medium pressure pipelines

SANS 347, Categorization and conformity assessment criteria for all pressure equipment

Cold galvanising of Hot Dipped Galvanised piping components is not allowed.



6.5.2. Specific Requirements

Blower House

The blower houses are pressurised to prevent dust and ash contaminants from entering the building.

The blower house are fitted with lifting equipment which will allow for the equipment within the blower house to be installed and removed.

The access door ways for the blower room are fitted with an automatically closing feature to ensure that the doors cannot be left open.

Sufficient space is allowed inside the blower house to facilitate operating and maintenance activities.

The blower house is fitted with pressurisation fans and louvre dampers which supply filtered air to supply the blowers and to pressurise the blower house preventing contaminants from entering.

Hopper Aeration Air Supply

Blowers are electrically driven.

The blowers are fitted with the following as a minimum: o An acoustic hood. o Suction and discharge silencers. o Inlet filter fitted to the intake piping. o Isolation vales o Non-return valve.

The Contractors design takes into account operational cycling between blowers in operation and blowers on standby.

Intake Piping

The intake piping (where applicable) for the blowers are taken from a clean location inside the hopper aeration blower house.

The intake piping is sized to give a minimal pressure drop.

The intake piping includes a silencer and the Contractor conducts a pipe stress analysis for hot and cold operation, deadweight and vibrational loads to optimise the spacing and the selection of pipe supports.

Piping is specified as per:

SANS 62 – 1 “Steel Pipes Part 1: Pipes suitable for threading and of nominal size not exceeding 150mm”

SANS 719 “Electric welded low carbon steel pipes for aqueous fluids (large bore)”.

Intake piping is hot dip galvanised in accordance with SANS 121 “Hot dip galvanised coatings on fabricated and steel articles – Specifications and test methods”.

Intake Filter System

A cartridge type air intake filter which can be easily and safely removed for replacement is fitted for the blowers.

Differential pressure monitoring equipment across filter elements is provided by the Contractor with the alarm and maximum differential pressure indicated.

Discharge Piping

The discharge piping delivers aeration air to the respective unit.



Discharge piping includes a safety relief valve, non-return valve and silencer immediately after the blowers.

Isolation valves are provided downstream of measuring and monitoring devices to enable isolation such that maintenance can be performed on them while the discharge piping is pressurised.

The Contractor conducts a pipe stress analysis for hot and cold operation, deadweight and vibrational loads to optimise the spacing and the selection of pipe supports.

The Contractor ensures the discharge piping is lagged for safety and to prevent condensation of air inside the discharge piping.

Discharge piping is sized to ensure a limiting velocity of 9 metres per second is not exceeded or a pressure drop of 2.5 to 50 Kilopascals per 100 meters of pipe is not exceeded.

The discharge piping downstream of each blower is fitted with:

A pressure transmitter.

A temperature transmitter.

A flow transmitter.

Areas of the aeration piping are to be able to be isolated such that maintenance can be conducted while the aeration system is operational.

The air supply to each hopper is able to be isolated while the rest of the air piping remains in operation.

Flow transmitters are installed to monitor the flow of air to areas of aeration air piping to allow for leaks and aeration pad failures to be detected.

The air supply piping to each of the aeration pads is fitted with a non-return valve to ensure that there is no back flow into the air supply piping if there is a failure on an aeration pads.

Piping is specified as per:

SANS 62 – 1 “Steel Pipes Part 1: Pipes suitable for threading and of nominal size not exceeding 150mm”

SANS 719 “Electric welded low carbon steel pipes for aqueous fluids (large bore)”.

Discharge piping is sized such that the velocity of air does not exceed 9 m/s and it does not exceed the pressure drop of 2.5 to 50 kPa per 100 metres of delivery pipe.

Discharge piping is hot dip galvanised in accordance with SANS 121 “Hot dip galvanised coatings on fabricated and steel articles – Specifications and test methods”.

Aeration Air Heaters

The air heaters consist of multiple banks of heating elements which have the ability to operate independently such that the desired heating capacity is obtained.

The heaters are located outside of the blower houses.

The design of the heater system ensures that the heater is distanced from the heater control panel and the control panel is located in a clean environment, e.g. control panel incorporated into the blowers’ control panel.

A junction box is located between the heaters and the control panel.

Silicon covered wires are used for the cables for the heaters to the junction boxes, normal cabling is used between the junction boxes and the control panel.

The silicon covered wiring is protected by a sheath (steel pipe or similar) which is sealed on both ends once installed.

The design of the heaters and the insulation takes cognisance of all maintenance activities which are carried out on the Plant. In addition:

The heaters boxes are IP65 compliant.

The heaters are mounted above the floor level, on plinths.

Hopper Aeration Pads

Aeration pad membranes are installed within a supportive casing that is designed to self-protect against foreign objects which may pass through the hoppers and damage the membrane.



The aeration membranes are supported and protected from the top and bottom by means of a grating to minimise movement, wear, and extend the life of the membrane.

A high temperature membrane fabric (up to 110°C for extended periods and up to 200°C for short periods) is used. Fabric containing asbestos is not permitted.

Hopper Aeration System Valves

Valves below 50 mm NB are ball valves with stainless steel as the material of construction.

Valves 50 mm NB and above are wafer type butterfly valves with a stainless steel disc. Each valve has a serial number stamped on the body of the valve. .

The Contractor supplies the following test certificates:

Material certificate

Pressure test certificate

Leak test certificate

Test methods used are stated on the certificates.

6.5.3. HVAC specific requirements

DX Air Conditioning units

The unit to be provided with the following as a minimum:

An ON/OFF facility with the ability to select full air conditioning and Fan operation only.

A fan speed selector with a HIGH/MEDIUM/LOW setting.

The controls are clearly marked and easy to operate.

The unit is provided with an adjustable temperature controller with an adjusting range of 20-25ºC. The sensitivity of this temperature controller are such that it controls in a differential band of 2ºC (adjustable 1 to 4ºC, factory set at 2ºC), 1ºC on either side of the set points. The temperature controller is clearly marked in which way to adjust the room temperature. The temperature controller switch on the heater or compressor automatically in accordance with the load.

The control facilities are installed within a suitable draw box recessed into the wall/partition, with the control cable reticulated within an enclosed conduit.

A package cooling unit system is supplied complete with the following:

R410A or equivalent refrigerant gas

Advanced control board

ON/OFF scroll compressor

EC plug fans

Condensing fan speed control (HP control)

Areolating rubber feet

Dehumidification control

Compressor anti-short cycle

Air flow switch

Dirty filter alarm

Evaporate leaving temperature control

Low ambient protection

G3 & F9 filters

Phase sequence relay

Free-cooling



Operating range

Fan delivery does not decrease more than 10% when filter dirty and the operation point are stable part of the curve.

Unit operate continuously without damage or malfunction for the following range of conditions at local altitude:

Condensing Unit: Entering Air Temperature : 0ºC - 52ºC A “low ambient” condensing control is to be incorporated in the unit if specified as such in the schedule.

Safety protection is to be provided for the fan motors as follows, unless otherwise specified:

Single phase motors: Thermal overload protection.

Three phase motors: Combined thermal overload and phase failure protection. Fan motors are non-overloading at any operating point of their performance curves.

Both indoor and outdoor units are to be fully protected and to fail safe. Minimum safety protection, caused by possible external abnormal conditions to be provided for the following, and require manual or automatic reset after fault occurrence:

High discharge pressure.

Low Suction pressure/anti-freeze protection.

Crankcase heater.

Thermal overload protection for all motors.

Current overload protection on compressor.

Re-starting time delay for compressor.

Auto re-starts on power supply interruption.

Reliability and availability

All components and casings to be designed for a service life of 15 years for local conditions based on a 24 hour daily operation.

All components which may come in contact with water (rain, condensate, sweating of compressor, etc.) are to be protected against corrosion in order to obtain the desired service life.

Technical restraints

The unit coils are provided with the following minimum requirements:

The AHU coil to be aluminium fins mechanically bonded to seamless copper tubes. The fin spacing to be greater than 2mm. Ensure no "water carry over" during any operation condition.

The outdoor coil must be hail-proof.

Coil and refrigerant piping to be protected from freezing in ambient temperatures down to -50C. Heating to be provided by a reverse cycle "heat pump feature" if specified as such in the schedule

Compressors may be either semi-hermetic, suitable for field servicing or hermetically sealed.

The unit electric heater shall have the following minimum requirements:

Manual reset thermal cut-out device set between 60 – 80 0C with reset button, labelled and operable without removing any terminal box cover.

Elements to have an adequate resistance to earth, with due regard to the possible condensation of moisture during the cooling cycle.

The refrigerant piping system is provided with the following minimum requirements:

Refrigerant pipe sizing calculations are to be submitted where the length exceeds 15 metres.

The necessary traps to be installed in the refrigerant lines to ensure oil return for applications where the outdoor unit is installed higher than indoor unit.

Flare connections to be used at the indoor and outdoor unit.



Three way valves with service port are to be installed at the outdoor unit for connection of standard refrigerant pressure gauges.

Fit a filter in the liquid line with a sight glass and moisture indication thereafter.

Provide facilities for charging the units with refrigerant and measuring the refrigerant pressures of the unit using standard refrigerant gauges.

Units which are not pre-charged are to be evacuated to a vacuum of not less than 4mm Hg before charging.

The insulation for the refrigerant piping to be of the "ultra-violet resistant" type. Insulation exposed to outside weather to be finished off with ultra-violet resistant plastic tape or paint.

Drainage of condensate from the units to be collected by the following means:

A pan of sufficient size to catch all condensate which may emanate from the unit.

Drainage via gravity feed from this pan to a suitable connection; or booster pump assisted drainage where indicated on the relevant drawings or in the accompanying schedule.

The drain pan to be fabricated from galvanised sheet steel and painted internally to prevent condensation on the external surface.

Drain piping to be fixed and routed to the nearest suitable drain point to ensure positive drainage.

Drain piping to be resistant or protected against weather elements or people traffic.

The electrics and controls shall have the following minimum requirements:

All electrically powered elements within the unit to have an adequate resistance to earth, with due regard to the possible condensation of moisture and comply with statutory requirements.

Interconnecting wiring from the outdoor unit to the indoor unit is to be via conduits or suitable special cable.

Power supply from the local isolator is to be protected against the elements by means of conduit or suitable cable.

Confirm adequacy of the power supply at equipment submission stage.

A manual override facility is to be provided on the indoor unit if a remote wireless

Temperature/control unit is offered.

Installation restraints

Install units in accordance with manufacturer's recommendations and be capable of being fitted into the spaces indicated.

The unit not to drum, vibrate or leak under any operating conditions. Noise level in the conditioned space through the operation of the unit at any operation point is not to exceed NC 40 with an 8 dBA room attenuation factor in each octave band.

All penetrations through building structures is to be sealed against ingress of water and air.

All piping/conduits/wiring/supports are to be neatly and securely fixed to the building structure. Method of fixing is to be submitted to Employer prior to installation.

Measurement to confirm equipment compliance with specification

Contractor is to submit with the tender certified performance tests of capacity and power consumption at either AREO conditions or local conditions by the SABS or a similar organisation.

Performance to be based on the actual mounting details and location where installed.



Performance testing of each unit to be done in a certified "on line" test facility. The minimum tests are to include compressor running amps, entering and leaving temperatures, a leak test, the heater amperage, all controls for function and calibration of thermostat. All results to be properly recorded against the serial number of the unit and signed off by the responsible person for quality.

Fans

Operating range

The operation point is to be in the stable part of the curve.

Safety protection is to be provided for the motors as follows, unless otherwise specified:

Single phase motors: Thermal overload protection.

Three phase motors: Combined thermal overload and phase failure protection.


The allowable maximum downtime for fans are to be so installed that replacement are not to take longer than 2 hours when executed by qualified building maintenance staff.

Contractor is to submit service-, maintenance, troubleshooting- and testing instructions in order to obtain acceptance. Documentation is indexed in accordance with the equipment part of the Operating & Maintenance Manuals.


The Fan is to be complete with standard flanges.

Bearings are to be of the permanently lubricated type.

Air flow arrow indicators to be installed for each fan unit.

Fan is direct driven or belt drive as required by equipment schedules, suitable for mounting at any angle and mounted on vibration areolation mountings.

Motor rating is not to be less than the maximum power required by the fan at any operating point between zero and break off capacity.

Fan casing are to be insulated with high density acoustic insulation to limit break out noise to the occupied space.

The fan motors are to be provided with manually adjustable speed controller to deliver the specified air quantity where required.


Install fan assembly in accordance with manufacturer's recommendations.


Contractor is to supply the necessary field testing instruments and detailed description of field testing arrangement to prove a capacity/performance measurement accuracy of ± 5% for the Fan Acceptance Testing.

Certified test results are to be plotted on the official published and certified equipment performance graph/table to confirm that claimed performance is achieved.

The various tests as required by the Quality Management System are demonstrated and accessible to the Employer at all times for monitoring.

Low pressure air distribution system

Operating range

Maximum allowable variation between actual air flow and specified air flow is not to exceed 5%.



Leakage is not to exceed 4% under operating conditions.

Ducting system is to attenuate the total sound power fed into the system by the fan to provide the specified noise levels in the spaces supplied by the ducting system either directly or indirectly (duct break out and noise or air outlet noise).

All isolating, fire, smoke and balancing dampers are to have external easy accessible position indicators, with locking and sealing means when required, and means of resetting after tripping.

Inspection doors are to be provided to inspect damper and/or equipment operation for which external indication is impossible or impractical.


Duct system control and safety equipment such as automatic dampers, booster fans, etc., requiring service and possible removal/replacement are to be installed in such a way that the downtime of the duct system does not exceed 1 hour when either service/repair or removal and re installation are required.

Duct system control and safety equipment requiring service, maintenance, trouble shooting and periodic replacement etc., are to be documented in accordance with the equipment part of the Operating & Maintenance Manuals.


The ducting system is to comply in all respects with:

SANS 1238 1979 "Standard Specification for Air Conditioning Ductwork

SANS 0173 1980 "Code of Practice for the Installation, Testing and Balancing of Air Conditioning Ductwork".

Low Velocity Duct Construction Standards-SMACNA.

SANS 10400 Section TT 43.2.

Additional sound attenuating elbows, attenuators, internal acoustic material are to be installed if a sound analysis - in accordance with Chapter 32 Sound and Vibration Control of ASHRAE 1984 System's Volume - for the actual sound power generation of the selected fan, selected fittings and duct construction details indicate that this are required to maintain the specified noise level in the space.

Flexible ducting complete with insulation are to be constructed of non-combustible material as required in terms of the building regulations provided that:

Approved combustible flexible connections are to be used where the length of such connection does not exceed 1.5m and such connection does not pass through any wall or floor which is required to have a specified fire resistance.

Approved combustible flexible joints of not more than 250mm in length may be used in any system room where such system room are protected by a smoke detection system.


Ducting systems are to be isolated from actual or potential vibration generating equipment and building components to eliminate transmission of vibrations.

Pressure testing

Duct work is to be pressure tested as follows:

The duct pressure is to be at least 2 times maximum operating pressure, or 150 Pa, whichever is the greater.

Smoke is introduced into the duct section under test.

All leaks letting out visible smoke are to be closed up with approved duct sealing compound.



A further pressure test are to be performed at the above specified duct pressure and leaks sealed until a maximum allowable leakage rate of 4% are reached, suitably de-rated for the volume handled by the duct section being tested.

Pressure testing are to be performed with the spigots installed, temporarily capped, but before the application of the external insulation.


The testing and balancing of the ducting system are to be executed under the control and supervision of an Employer.

The method instrumentation, procedure, recording are to be documented in a Testing, Balancing, Adjusting Procedure Book.

Minimum requirement for procedure are to be submitted for acceptance in accordance with contract conditions, SABS Code of Practice 0173 1980 and/or Procedural Standards National

Environmental Balancing Bureau and/or C.I.B.S. Code of Practice.

On completion of testing and balancing of the ducting system a signed report are to be submitted by the Contractor listing all the results to prove that the system are balanced as specified.

Contractor is to submit proven and necessary calibration certificates that measurements have a 5% accuracy.

Refrigerant piping system

The refrigerant piping system is to be designed and engineered in detail in accordance with the design criteria laid down in:

Trane Reciprocating Refrigeration Manual 1977, and/or

Carrier Systems Design Manual Piping Design Chapter 3, Refrigerant Piping.

The refrigerant accessories are to be fully catalogued products and the documentation to include performance curves or selection tables, for the expected range of operational conditions.

Submit certified detailed selection shown on these performance tables or curves.

Submit full documentation and calculations for acceptance of equipment submission, showing all detailed pressure loss and velocity calculations for the entire refrigerant piping system and accessories under full load and minimum load conditions, including the temperature/pressure curves and balance points for evaporator, compressor and condenser.

Where reduction in pipe size are necessary to provide sufficient gas velocity to entrain oil upwards in vertical risers at part load, and at full load the pressure drop exceeds specified design limits, a double riser incorporating an oil trap are necessary.

The system is to be designed:

To minimise loss of lubricating oil from compressor at all times.

To ensure lubricating oil return to compressor, at the same rate at which it leaves under all load conditions.

To prevent lubricating oil being trapped in system.

To prevent liquid refrigerant from entering the compressor during operation and shutdown.

For minimum pressure drop and noise generation. The suction, discharge and liquid lines are to be sized so that the pressure drops do not cause a change in saturation temperature of refrigerant greater than 1,1 degrees C in each respective line.

For handling the specified capacities from 100% down to minimum load at specified suction and discharge/condensing temperature.



Refrigerant piping accessories and connections are to be selected to ensure no leakage from refrigerant piping system during its operational life.

Refrigerant piping system is to be complete with all necessary isolating valves to enable repairs and maintenance to be carried out on any one section of the system.

The refrigerant accessories are to be so connected and installed into the refrigerant piping system that either a sub component replacement or total removal or reinstallation of the accessory does not take longer than 2 hours by qualified refrigeration mechanics.

Piping system, including accessories, thermal insulation, hangers, supports and vibration isolators are selected and installed to give a minimum working life of 15 years under normal building service conditions.

The entire refrigerant system is to be subjected to a leak pressure test with a suitable gas, e.g. clean dry air or nitrogen. It is permissible to add system refrigerant to enable leakages to be more easily detected.

Prior to carrying out this test, the Contractor verifies by examination of the various parts of the components of the system that the test pressure to which they were subjected at the manufacturer's works, are adequate for the required duties.

Incorporate a safety valve or rupture disc in the piping system.

Rupture discs are to have a specified and certified bursting pressure at a specified temperature and marked accordingly on the disc.

The system is to comply with the Safety Code for Refrigerant Piping ASA B31.35–1962, with the requirements of ASME, with Occupational Health and Safety Act as amended, and with local authority’s by laws.

Piping to be stored and handled on site to prevent dirt from entering piping system. Open ends are to be plugged.

Tubing is to be protected against oxidation during silver soldering by use of dry nitrogen flowing through tubing. Solder to be silver solder.

Where required for connection to gauges and control devices, tubing not larger than nominal 10mm may be type K soft (annealed) with flared tube fittings suitable for high pressure.

Accessories connected to copper tubing are to have solder type ends or flanged ends and soldered flange adaptors.

Piping is to be installed so as to allow for expansion and contraction. Suction and discharge lines are to be installed so that the first point of support is 6 pipe diameters in each of three directions from the unit.

System vibration areolation are in accordance with Sound and Vibration Control requirements

Thermal insulation of suction line is to be in accordance with insulation requirements

Piping is to be installed parallel or perpendicular to building construction, while maintaining the required gradients.

Refrigerant piping between indoor and outdoor units are to be supported along its entire length by a galvanised perforated cable tray of sufficient size to allow pipe work to be neatly laid out and insulated. The cable trays are to be supported clear of fixing surface by galvanized brackets allowing air space between cable tray and mounting surface.

Where piping and insulation are exposed to damage or located externally to the building, a galvanized sheet metal cover having a minimum thickness of 0.8mm are neatly formed and secured to the cable tray brackets. Joints are to be lapped by a minimum of 30mm and to have a minimum clearance of 10mm over insulation.

All necessary pressure gauges are to be installed in refrigerant lines to check pressures and temperatures for load monitoring function of various accessories and possible blockages of strainers.

Isolate accessories requiring regular inspection, cleaning and removal by shut off valves to enable this without pump down of the entire refrigeration system.



Accessories

Liquid receivers are offered with the following minimum requirements:

Each receiver is to have sufficient capacity to hold all refrigerant in the system to which it are connected, except that in systems having two or more separate refrigerant circuits, cross connected by pump out piping.

The receiver is to have sufficient capacity to hold all refrigerant in the largest circuit. Receiver capacity is to be based on not over 85% of its internal volume being occupied by liquid. Receiver is to be complete with liquid level indication.

Liquid Suction Interchanger shall have the following minimum requirements:

Heat exchangers for field assembled systems are to be the standard products of a reputable manufacturer. Field fabrication of heat exchangers is not permitted.

Heat exchangers for field assembled systems are to be of the shell and tube, shell and coil or double tube type. Tubes are to be seamless copper, plain or with integrally formed fins. Shells are to be welded steel, conforming to the requirements of the latest edition of the Mines and Works Act or the Machinery, Factories and Building Work Act and Regulations, covering pressure vessels. Gas passages are to be arranged so as to prevent trapping of oil. Liquid gas heat exchangers for Refrigerant 12 are to have sufficient surface to ensure heating the gas to not less than 18.5 degrees C at the outlet. Liquid pressure drop are not to exceed 21 kPa and gas pressure drop not to exceed 3.5 kPa.

Refrigerant Driers have the following minimum requirements:

Refrigerant driers for field assembled systems are to be of the angle type with removable cartridges that can be renewed without disturbing pipe connections. Driers are to have brass or steel bodies and solder joint connections. Bonnets are to be flanged and bolted. Cartridges are to be charged with dry silica gel or activated alumina, held securely in place without restraining normal expansion, and provided with suitable means for distributing the refrigerant evenly through the charge. Unless otherwise indicated driers are to be installed in liquid lines close to the receiver outlets and be provided with valves on the inlet and outlet connections. Valved by passes are also to be provided unless the driers are of a type guaranteed by the manufacturer to operate indefinitely without dusting of the desiccant or appreciable increase in pressure drop. Install a liquid sight glass and moisture indicator of the colour change type in the liquid line, close to each drier.

Select each drier so that the pressure drop through the drier does not exceed 14 kPa when operating at full connected evaporator capacity.

Drier cartridges are not to be installed until after pressure and vacuum tests have been completed but immediately prior to charging.

Thermostatic Expansion Valves have the following minimum requirements:

In field assembled systems, each evaporator circuit are to be provided with a thermal expansion valve of the gas charged type.

Valves are to have external equalizer connections, external superheat adjustments with seal caps and solder joints or flanged pipe connections.

Valves are to move from fully open to fully close with not more than 3 degrees C superheat change. Superheat setting is to be 6 C at full load. Each valve is to be provided with an external strainer, regardless of any internal strainer that may be incorporated in the construction. Strainers are to be as specified under "Refrigerant Strainers".

Oil Separators have the following minimum requirements:



Each reciprocating compressor having suction and/or liquid mains more than 15 m long is to be equipped with a discharge line oil separator.

Separators are to be made of welded steel and have an effective impingement type separating element, an oil sump and a float operated return trap connected to them to return oil to the compressor automatically.

Refrigerant Stop and Shut off Valves have the following minimum requirements:

Refrigerant stop valves generally are to be of the back seating key operated, sealed cap type. Valves which are opened and closed in regular operation are to have packles type hand wheels.

Refrigerant strainers have the following minimum requirements:

Refrigerant strainers are to be of the angle type, cleanable without disturbing pipe connections. 40 mm N.B. strainers and smaller are to have brass bodies and solder joint connections. 50mm N.B. strainers and larger are to have brass or rust proofed steel or iron bodies and flanged connections. Connections are to be flanged and bolted.

Screens are to be bronze metal with perforations not larger than 0.25 mm for liquid lines and 0.5mm for gas lines. The free area of each screen is not to be less than 5 times the area of the strainer inlet pipe.

Charging valves are to be located in the liquid line between the receiver shut off valve and expansion valve.

Provide external gauge connections at inlet and outlet of condenser, evaporator coil and compressor to enable evaluation of system pressures at commissioning and for normal maintenance inspections.

All gauges are to be connected to the refrigerant piping system through isolating shut off valves.

Liquid indicators are to be of sight glass - double port with seal cap type - of full size in the main liquid line before the thermostatic expansion valve.

The solenoid valves are to have manual override to enable the system to continue to operate in case of solenoid coil failure.

Vibration Isolators (Flexible Connectors) have the following minimum requirements:

Suction and discharge lines from the compressor are to be fitted with flexible connectors of the bronze braided hose type, having sweat ends, to fit over copper tubing having the same size as the line in which they are installed.

Locate flexible connector as close as possible to the compressor and parallel to the compressor shaft. It shall not be subjected to compression or extensions.

For refrigeration installation utilising a remote air cooled or evaporative condenser, hot gas mufflers are used to remove pulsations from the hot gas discharge and thereby reduce noise and vibration from the piping system. The hot gas muffler must be installed to prevent accumulation of oil.

Testing, charging and evacuation

Complete system to be pressure tested with dry nitrogen and leak test carried out. Test pressure to be maintained for 24 hours with no loss in pressure. Complete system to be evacuated and proved to be free of moisture. The system is able to stand for a minimum of 12 hours with no change in Vacuum. System to be liquid charged on high side following purging of connections to the estimated total charge. Minor adjustment to charge is to be carried out during the12 hour test run.

The following method is recommended for pressure leak testing:

Use a mixture of nitrogen & trace refrigerant in conjunction with one of the following suitable leak detection methods: Acceptable leak test methods include, Liquid submersion testing, soap bubble leak detection, fluorescent leak detection & electronic leak testing or any acceptable standard.

Pressurise the complete system with dry nitrogen & leak test using any acceptable method.



Having ensured there are no leaks using A or B above, the system must be pressurised to a safe test pressure. Observe over a period of time, relative to the size of the system that no pressure drop occurs, having due regard to temperature variation throughout the system.

After determining that there are no refrigerant leaks when the system is pressurised, the system must be evacuated to remove moisture & air. Evacuation must be deep evacuation method, or triple evacuation using dry nitrogen only as the moisture absorber. To be witnessed by Employer’s representative.

DEEP VACUUM METHOD: Pull a deep vacuum to a pressure of less than 13 Pa absolute (100 microns of mercury). After isolation the vacuum pump, allow the system to stand for 60 minutes to ensure the vacuum are maintained at or below 16 Pa absolute (120 microns of mercury), OR

TRIPLE EVACUATION METHOD: Use a vacuum pump to pull a vacuum to a pressure of at least 260 Pa absolute (2,000 microns of mercury). Break the vacuum with dry nitrogen & allow the system to stand. Re-evacuate the system & repeat the procedure twice more, breaking the vacuum each time with dry nitrogen.

The final evacuation should be held for twelve hours with no loss of vacuum. After the system has been evacuated the vacuum pump should be isolated from the system and as guide, with constant ambient conditions the vacuum should not rise more than 13 Pa absolute (100 microns of mercury) in one hour. A greater rate of rise may indicate a leak. Absolute vacuums should be measured using accurate measuring equipment selected for the specific application.

Expansion valves and solenoids are to be stripped before welding refrigerant pipes so as to avoid overheating and associated damage to seals, or they are to be kept at constant temperature by means of damp rags.

Should the refrigerant piping run longer than normal, the amount of refrigerant oil is to be increased in the pipe system as per the manufacture’s specification.

Stand-alone control system

The stand-alone control system is to be of the direct digital control type and be configured with the following functions. The stand-alone micro-processor based plug in modules typically control peripheral devices, elements and components in a subsystem and shall:

• Provide means to change set-points, integrating and differentiating time, and proportional bands through portable plug in operator terminal.

• Transmit relevant data to other stand-alone controllers installed if required to do so. • The control system is to be employed and arranged in such a way that staged start up at sub

system level is provided for staged commissioning.

Operating range

Sensitivity, speed of response and throttling range of the individual items of the control system is adjustable so that the controllers maintain steady conditions without hunting or drifting within the specified control values.

Safety and alarm

In case of any control system malfunctioning or function interruption, an alarm signal is given by field adjustable, programmable, audible and visual alarms and the control device must remain in its last controlled position prior to the failure.

Points in alarm are accessed on the stand-alone controller by using menu on screen. The list of signals are as follows:

• Controls • Dx. package unit automatic/manual selection switch • Room return air temperature thermostat controlling 3 way valve at close control • Heater stop/start per step • Ventilation fan motors start/stop • Fire dampers re – opening • Indications



• Fan running/stop/tripped indications • Duty selection position • Change over to standby plant activated/not activated • Individual Dx. Package Unit air flow failed/normal • Filters clean/dirty • Electrical switchboard and supply monitoring signals • Fire dampers open/close signals • Alarms at (Visual at HMI) • High and low air conditioned zone temperatures. • Dx. Package Cooling unit trip • Fans trip No airflow (priority alarm for operator investigation)


The equipment are so constructed and components installed, connected and documented so that with required spares available and diagnosis methods used, the maximum breakdown interference for any card or board replacement will be limited to one hour.

The Contractor demonstrates at tendering stage how the "Mean Time To Return" the system to its operational status is achieved with the aid of trouble shooting flow charts to diagnose and repair the sub system.

During pre-handover (commissioning and testing) "Downtime" of the control system and/or during actual "Downtime" during the period that the Comprehensive Service and Maintenance Contract is in force, the Contractor shall operate the entire system for as long a period as may be required to provide satisfactory performance at all times in the occupied spaces served by that system for up to 24 hours a day continuously.

The Contractor provides the operator(s) and equipment required for testing and operating the system. The Employer may assign operating personnel as observers but such observation time shall not be counted as instruction time.

The Contractor's operator(s) are fully conversant with the system operation and experienced in running similar installations.

The Mean Time between failure of the overall system or parts of the system is offered at a minimum of 7.5 years. Not more than 5% of the system components fail in any one year.

At tender stage the Contractor submits the interpretation of the point list, major qualifications and brief summary of the proposed system offered.

The Contractor submits at equipment submission stage full details of the proposed:

Fault detection and identification methods

Fault correction methods

Spare parts availability

Documentation

Operators and Maintenance training. During construction, prior to handover full Operating, Trouble Diagnosis, Service and Maintenance Manuals, together with training aids and procedures are submitted.

The Contractor submits full details how and what integrity checks are continuously performed concurrent with normal operation and the subsequent actions are fully described and the influence of these procedures on achieving the claimed "Mean Time to Return" to normal operation.


The equipment requirements is such that the control system hardware is readily accessible, modular, plug in connected, to allow for easy fault diagnosis and ease of maintenance on a remove and replace basis to limit downtime to minimum. Adequate space is provided around all items for easy removal of parts.

The system has self diagnostic characteristics to determine fault conditions.

The stand-alone controller level and interface is designed as follows:



The system is designed to utilise only standard sensors, controllers transducers, servo actuators, for the industry which have been field tested for at least 2 years. The control system does not only incorporate its own sensors and controllers where applicable, but also use the standard instrumentation, sensors and control equipment supplied as "standard" on equipment such as air cooled condensing units, in order that the performance of all the components of a subsystem can be test logged and commanded at the central operator's terminal.

All actuators, operating valves, dampers, etc., controlling the capacity of components and/or subsystems are equipped with manual operators to maintain control during power failure or interruption. It is impossible to use the manual operator when the power is switched on. If the actuator is switched back to automatic control the manual operator knob shall automatically disengage.

All interface between sensors, components, relay boards, capacity controllers, etc., is via plug in terminal factory pre tested connector strips in the MCC's or interface panels.

The accuracy of the sensors, controllers, outstations and management level is of such a standard that the discrepancy (measuring error) between actual and measured value never exceed 2% of the operating rang.

All the field instruments positioned in the battery room are Exn rated


Every care is taken to protect material, either fixed or unfixed, from damage, ingress of dust, water and moisture. The entire installation is in "as new" condition at handover.

All panels are totally enclosed, dust, damp and vermin proof.

The system is designed for location in mechanical system rooms with maximum indoor temperature of 40°C.

The system is designed to provide continuity and correct operation during abnormal conditions caused by over voltages, electromagnetic induction, spiking input/output and any other "normal" interference found in commercial buildings through switching of fluorescent lights, operation of other control equipment, operation of welding machines, somewhere in the building, etc.

The installation in its entirety shall comply with regard to electrical safety, supply interference and suppression requirements, with SABS regulations.


After successful demonstration of control operation of each sub system including accuracy of sensors, a total system demonstration is performed. This demonstration, having satisfactorily met previously approved submittals, shall with the Employer’s written acceptance, allow commissioning of the system for on line operation.

The Employer takes over the control system upon successful completion of the following by the Contractor:

Training of the system's operator and demonstration that the operator is fully conversant with the system trouble diagnosis and corrective actions.

The proper functioning of the entire stand-alone control system is documented in a formal handover/test report written and signed by the control system's responsible Employer representative and accepted and countersigned by Contractor.

The control system tenderer shall submit the pro forma test/handover report at tendering stage.

No handover of system will take place without submission to and acceptance by the Employer of this formal handover report.



Power Supply interruptions

The Contractor ensures that the supplied equipment are capable of safely shutting down the system without damage in the event of partial or total loss of electrical power, and must be designed to accept a sudden restoration of electric power, without damage and without operator intervention.

6.5.4. Particular Specifications pertaining to SANS 2001

The table below indicates particular specifications pertaining to SANS 2001-DP2 and must be read in conjunction with the code.

1. Clause 2. Particular Specification

4.1 Materials

4.1.2.1.3 A certificate that certifies compliance with the requirements of SANS 62-1 and SANS 62-2, as relevant, is required for each consignment of pipes and fittings.

4.1.2.2.2 A steel maker’s certificate covering all steel used in the manufacture of the pipes is required.

6.5.5. Tests and Inspections

There is a one to one alignment between the method statements and the ITP’s. The method statements and the ITP’s are submitted together for acceptance.

The Contractor performs the following site acceptance tests:

• Pressure test on all piping components; • Blower and motor vibration tests according to BS ISO 10816; • Confirm flow rate to each user; • Confirm pressure at each user; • Confirm temperature at each user; • System performance at minimum and maximum system flow rate; • Confirm that all control valves are operated within the valve's control range. • 1 month system reliability run;

The Contractor includes the following on his ITP:

• Acceptance of all relevant documents and drawings; • All inspections and tests required by the relevant codes and standards. • Confirmation that the manufacturing data books have been reviewed, accepted and available on

Site. • Confirmation of the Permit to Work. • Inspection of components on delivered to Site. • Anchor bolt position checks; • Position and dimension checks on all items before being grouted. • Alignment check for all piping connected to fixed components (vessels, pumps etc.) • Inspections during flushing and pressure testing. • Plant inspection before safety clearance. • Issuing of all certificates. • All site acceptance tests;

6.6. Electrical engineering works

Electrical Equipment will be supplied by Others and issued for use to the Contractor. The contractor is responsible for interphases/ coupling to the electrical motors, switchgear and cabling where applicable and commissions the entire system.



The works done by Others complies with:

• 240-50237155, New MV Motor Procurement Standard • 240-53114214, Cabling and racking standard. • 240-55714363, Small power and lighting standard. • 240-56227443, Requirements for Control and Power Cables for Power stations Standard. • 240-56356396, Earthing and lightning protection standard. • 240-57617975, Procurement of Power Station Low Voltage Electric Motors Specification Standard • 240-56227516: LV Switchgear and Control Gear Assemblies and Associated Equipment for Voltage

up to and including 1000V AC and 1500V Standard • 240-56227426: Management of Power Station MV and LV Protection and Settings Standard • 240-56357424: MV and LV switchgear Protection Standard

6.7. Process control and IT works


• 240-56355754: Field Instrument Installation Standard • 240-56355843: Pressure Measurement Systems Installation Standard • 240-56355888: Temperature Measurement Systems Installation Standard • 240-56356396: Earthing and Lightning Protection Standard • SANS 60529:2013: Degrees of protection provided by enclosures (IP Code) • 240-56355815: Field Instrument Installation for Junction Boxes and Cable Termination • 240-56227443: Requirements for Control and Power Cables for Power Stations Standard • 240-56355815: Control & Instrumentation Field Enclosures and Cable Termination standard • 240-56355466: Alarm Management System Guideline • 240-56737448: Fire Detection and Life Safety Design Standard • 240-61227631: Piping and Instrumentation Diagram Standard • 240-71432150: Plant Labelling Standard

6.8. Plant labelling and descriptions

All the plant equipment is labelled in terms of the existing plant labelling system.

6.9. Other [as required]



7. List of drawings

Drawings issued by the Employer

This is the list of drawings issued by the Employer at or before the Contract Date and which apply to this contract. Note: Some drawings may contain both Works Information and Site Information.

Drawing number Revision Title



APPENDIX A DOCUMENT



DESCRIPTIONS

Concept Design report

The Concept design report consolidates all the inputs and outputs from the concept design stage. The report template is given in 240-49910679

For water distribution systems it is important to address the following specific items.

System description, a high level statement of the business need, aligned to the organisational strategy, with a focus on the high level processes, linking it to the business objectives and the process objective.

The water sources; The users of the water with approximate flow rates Operating concept (e.g. feasibility of gravity flow).

Basic design report The basic design report consolidates all the inputs and outputs from the basic design stage. The report template is given in 240-49910705 For water distribution systems it is important to address the following specific items.

Design Codes to be used. Applicable standards Applicable Specifications and drawings Equipment requirements: The equipment requirements provide basic

requirements for the selection of equipment. The detail within the schedule is dependent on the project strategy being used.

List of documents available for the existing design across all disciplines List of all documents that needs to cancelled and/or updated for the new design

across all disciplines

Process Design report

The Process design report consolidates all the inputs outputs from the process design stage.

For water distribution systems it is important to address the following specific items.

Provide enough information to allow the different disciplines/design authorities to start with their detail design.

Design parameters (Design Flow, Pressure, Temperature etc.)

Hydraulic analysis in enough detail to finalise the PFD and P&ID. This is done with computerised software. The analyses should use the input information generated above. Copies of the node diagrams input and output data (including pump curves) will be included in the report.

System resistance calculation for pipework and NPSH available for pumps

Mass and energy balance calculations,

The Hydraulic analysis can be documented in a separate report.

Mechanical Detail design report

The report template is given in 240-49910707

Detail design of the following is completed in sufficient detail for procurement and manufacture:

Supports

Pipe racks

Plinths for pumps, equipment, racks, supports and

Thrust Blocks

Hangers

Tanks

Valve chambers

Arrangement and layout drawings

Specification/s for equipment Detail design calculations must be included. Specialised calculations like pipe stress analysis can be documented in a separate document.

Overview diagrams Diagram providing a comprehensive view of the system with a low degree of detail. Also see IEC 61355 - Collection of standardized and established document kinds No. D00200

http://std.iec.ch/iec61355/iec61355.nsf/(sysSymbolEn)/D00200?Opendocument

http://std.iec.ch/iec61355/iec61355.nsf/(sysSymbolEn)/D00200?Opendocument



Overview diagrams of the existing plant must be created if it does not exist

Process flow diagrams

The PFD represents a process or a process plant with the aid of graphical symbols interconnected by flow lines. The graphical symbols represent equipment and the lines represent mass and energy flows or energy carriers.

As a starting principle of specifying what a PFD shall contain, it should be stated that each PFD shall show all the major pieces of equipment, the main interconnecting piping and the key instrument control loops used in a process. The mature PFD shall also provide process condition information, process stream compositions as well as information pertaining to key utility streams either directly on the PFD or in an accompanying table. 240-60782552.

If this is not available for an existing plant, an As-Is PFD will be developed by the designer.

P&ID’s The piping and instrument diagram (P&ID) is based on the process flow diagram and represents the technical realisation of a process by means of graphical symbols for equipment and piping together with process measurement and control elements 240-61227631.

If this is not available for an existing plant, an As-Is P&ID will be developed by the designer.

Control philosophy The purpose of this Control Philosophy is to communicate clearly to designers and users of the processes, "HOW" these processes will be controlled and "WHAT" will be done to monitor the effectiveness of these processes. This process starts with the development of a plant operating concept at the start of the concept design.

The document is providing information about the behaviour of the control system in operation. The document describes in words and tables the operation of the plant as intended by the designer. This document conveys the designer’s intent to the C&I engineer to design his system. Sometimes the document is referred to as a control narrative or operating control description 240-60782527. The following should be considers when developing a control philosophy:

System overview

System states and modes

Sequencing for start-up and shutdown

Process measurements (including response characteristics and accuracies)

Operator information display

Equipment interlocking/logic diagram

Process control and trip set-points

Alarm requirements and responses

Operator manual control actions

Automation system responses

Data capturing

Equipment protection

Control simulation

Control verification

Equipment lists/schedules

The coded P&ID is an important reference for all the lists to identify the equipment. The equipment is identified according to the applicable Eskom coding system and together with the P&ID are important conveyors of information to other disciplines.

Plant coding, the cornerstone of all configuration management and other management information systems is of utmost importance and the standardized application thereof cannot be overemphasized.

The KKS plant coding system has been adopted by Eskom and all Power Plants subsequent to Matimba will be coded with KKS (Corporate directive EVD 1085). Other coding standards are used on older stations and the Designer shall establish which system is in use.



Configuration Management

Label list for equipment C&I

Control & Instrumentation Instrument Schedule Template 240-61379718 Control & Instrumentation Drive & Actuator Schedule Template240-61379755. Virtual signal list 240-72344339 Panel interface list 240-72350241

Electrical

240-56227927 Electrical Load List Template Mechanical

Mechanical Equipment list template 240-55864360 serves as examples to the creation of the mechanical equipment lists

Equipment Specification

Equipment specifications provide more detail than the Equipment lists. The equipment specifications provide enough information for an equipment supplier to supply the correct equipment. This includes critical dimensions, equipment standards and all the information which the equipment standard requires the purchaser to supply.

OEM Equipment Data sheets

Data sheets are required from the OEM. These data sheets reflect the main characteristics for components including the model number.

3D Model A representation of the plant in three dimensions, using a software package specially developed for the purpose.

Conceptual plant layout drawings

Indicate with blocks and lines the position of the, to be designed or upgraded plant. Existing structures and interfacing systems need to be indicated where applicable.

Basic Plant Layout drawings

Drawing showing the location of sites, structures, buildings, spaces, elements, assemblies or components.

Plant Layout Drawings

Drawing showing the designed plant location including structures, buildings, spaces, elements, assemblies or components.

Pipe and cable routing drawings

Arrangement drawing on which the location of pipe routes, road crossings, cable and pipe tunnels, trays, ducts, trunking systems, pipe racks etc. are presented

Servitude defining drawings

These drawings provide information regarding geographical areas reserved for specific equipment/plant and operating / maintenance access.

Arrangement drawings

Drawing showing the relative or absolute location of objects Presentation mainly using the drawing form by showing, usually to scale, the objects and their relative position to each other.

These drawings include plans, sections, cuts, sketches and views.

This is a document providing information about shape, dimensions, placing and fixing of equipment, necessary for its proper installation.

Piping Isometric drawings

Pictorial representation of a piping assembly, usually in isometric axonometric or perspective representation, in which components are drawn to the same scale and correctly oriented relative to each other, but are separated from each other in their correct sequence.

This is drawings which provide all necessary information for manufacture and installation of the pipe spools.

Detail drawings Drawing depicting a single component and which includes all the information required for the definition of the component for manufacture. This can be a tank or vessel drawing for manufacture, ladders and platforms etc.

Fire Protection and Detection Assessment

The fire protection and detection assessment are done in accordance with 240-54937439.

FMECA study Failure Mode and Effects Analysis (FMEA) is a bottom-up analysis of a product or system to identify potential failure modes, failure causes and subsequent failure



effects on system performance. FMECA (Failure Mode, Effects and Criticality Analysis) is an extension of FMEA in order to include a means of probability of failure occurrence to provide failure criticality.

FMEA is described in more detail in a separate guideline, Failure Mode and Effects Analysis Guideline, Eskom document number 240-49230046.

HAZOP study Hazard and Operability (HAZOP) 240-49230111 analysis is a detailed hazard and operability problem identification process, carried out by a multi-disciplinary team under the guidance of an analysis leader. HAZOP deals with the identification of potential deviations from the design intent, examination of their possible causes and assessment of their consequences.

RAM Report/Analyses

System RAM (Reliability, Availability and Maintainability) Analysis refers to system evaluation in terms of reliability, availability, maintainability, life-cycle costs, throughput, etc. It includes modelling of the system using reliability block diagrams, model verification and assigning of reliability and maintainability (i.e. uptime and downtime) data to individual blocks. Reliability block diagrams show the relationship between subsystems in terms of success paths (i.e. series, parallel and other complex configurations). System RAM Analysis is typically performed using Monte Carlo simulation where a deterministic model is repeatedly evaluated.

In simple terms, RAM requirements are considered the upper level overarching requirements that are specified at the overall system level. It is often necessary to decompose these upper level requirements into lower level design-related quantitative requirements such as Mean Time Between Failure/Critical Failure (MTBF or MTBCF) and Mean Time To Repair (MTTR). These lower level requirements are specified at the system level; however, they can be allocated to subsystems and assemblies. The most common allocation is made to the Line Replaceable Unit (LRU), which is the unit that has lowest level of repair at the field (often called organic) level of maintenance.

Reliability Engineering refers to the Engineering discipline which addresses reliability and maintainability of a product or system during its total life-cycle. Reliability Engineering Analysis refers to the different analyses to be used for specification, allocation, designing-for, evaluation and/or measurement of reliability and maintainability of a product or system. These analyses are primarily applicable during system design but can also be used during operations and maintenance.

Reliability, Availability and Maintainability (RAM) specification refers to the specification of, primarily, quantitative reliability, availability and maintainability parameters. This activity should be performed as part of requirements analysis and, as such, be performed early during product or system development. It should include aspects such as RAM metrics, failure definitions, failure distributions, user profiles, environmental profiles, etc.

The Contractor performs a RAM study in accordance with 240-52844017, System RAM Analysis Guideline.

ESKOM HOLDINGS SOC Ltd CONTRACT NUMBER ____________ PROJECT & CONTRACT TITLE

PART C1: AGREEMENTS AND CONTRACT DATA PAGE 97 C1.2B ECC3 CONTRACT DATA PART 2

PART 4: SITE INFORMATION

Document reference

Title No of pages

This cover page 1

C4 Site Information

Total number of pages

ESKOM HOLDINGS SOC Ltd CONTRACT NUMBER ____________ PROJECT & CONTRACT TITLE

PART C1: AGREEMENTS AND CONTRACT DATA PAGE 98 C1.2B ECC3 CONTRACT DATA PART 2

PART 4: SITE INFORMATION

Core clause 11.2(16) states “Site Information is information which

describes the Site and its surroundings and

is in the documents which the Contract Data states it is in.” In Contract Data, reference has been made to this Part 4 of the contract for the location of Site Information. 1. Description of the Site and its surroundings

1.1. General description

Camden Power Station is a coal fired power station built in the early 1960’s and it is situated near Ermelo on the Mpumalanga Highveld, approximately 250 km from Johannesburg on the N2 towards Piet Retief. Camden Power Station was mothballed for 18 years and was returned to services since 2004. It has eight units of 200 MW capacity per unit. The Site is the areas listed below and adjacent areas:

The Ash Hopper area and immediate adjacent areas

The Ash Pump area and immediate adjacent areas

The Ash Sump area and immediate adjacent areas

The Blower Houses area and immediate adjacent areas

The AHP slurry pipeline servitude and immediate adjacent areas along the servitude

The AHP AWR pipeline servitude and immediate adjacent areas along the servitude

The Site Offices and immediate adjacent areas

The SWS areas and immediate adjacent areas

The SWRST area and immediate adjacent areas Refer to Drawing 15032/73-00-01. 1.2. Existing buildings, structures, and plant & machinery on the Site Refer to Drawing 15032/73-00-01.

The Contractor will familiarise himself with all of the adjacent structures and layouts of existing buildings in the area and around the works at the site clarification meeting.

1.3. Subsoil information Refer attached Geotechnical report 1.4. Hidden services N/A 1.5. Other reports and publicly available information