2009-11-27 3.2

Eskom Holdings Limited Medupi Power Station Contract Number : 4600011472

Employer’s Requirements Specific to the Works Section 3: 3.2

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MEDUPI POWER STATION

EMPLOYERS REQUIREMENTS SPECIFIC TO THE WORKS Section 3.2

TABLE OF CONTENT

3.2.1 INTRODUCTION......................................................................................................... 8

3.2.1.1 CONTROL AND INSTRUMENTATION DOCUMENTATION STRUCTURE ............ 8 3.2.1.1.1 SPECIFICATION STRUCTURE AND CONTRACTOR INSTRUCTIONS ...................... 8

3.2.2 SPECIFIC ABBREVIATIONS AND DEFINITIONS...................................................... 9

3.2.2.1 ABBREVIATIONS.................................................................................................... 9 3.2.2.2 DEFINITIONS........................................................................................................ 12

3.2.3 WORK TO BE PERFORMED AND EQUIPMENT AND PLANT TO BE PROVIDED BY THE CONTRACTOR FOR THE WORKS ................................................................................. 16

3.2.3.1 OVERALL SYSTEM TECHNICAL REQUIREMENTS............................................ 19 3.2.3.2 PROJECT STANDARDS....................................................................................... 20 3.2.3.3 CONTROL AND INSTRUMENTATION ARCHITECTURE..................................... 20

3.2.3.3.1 CONTROL AND INSTRUMENTATION SYSTEM BREAKDOWN................................ 20 3.2.3.3.2 CONTROL AND INSTRUMENTATION FUNCTION GROUP BREAKDOWN.............. 24

3.2.3.3.2.1 Power Island control and instrumentation System ............................................................................ 2625 3.2.3.3.2.2 Balance of Plant control and instrumentation System....................................................................... 2826 3.2.3.3.2.3 Miscellaneous SYSTEMS................................................................................................................. 3028

3.2.3.4 PROJECT EXECUTION METHODOLOGY ....................................................... 3129 3.2.3.4.1 GENERAL ................................................................................................................. 3129 3.2.3.4.2 EXPERTISE / EXPERTS PROVIDED BY THE CONTRACTOR.............................. 3230 3.2.3.4.3 POWER ISLAND 6 METHODOLOGY ...................................................................... 3331 3.2.3.4.4 BALANCE OF PLANT METHODOLOGY.................................................................. 3331 3.2.3.4.5 SYSTEM ENGINEERING ......................................................................................... 3432

3.2.3.4.5.1 GENERAL ........................................................................................................................................ 3432 3.2.3.4.6 TECHNICAL CLARIFICATION.................................................................................. 3735 3.2.3.4.7 PRODUCTION ENGINEERING................................................................................ 3836

3.2.3.4.7.1 GENERAL ........................................................................................................................................ 3836 3.2.3.4.7.2 FACTORY ACCEPTANCE TESTING ............................................................................................ 3836

3.2.3.4.7.2.1 PRE-FAT ...................................................................................................................................... 3937 3.2.3.4.7.2.2 FAT............................................................................................................................................... 3937

3.2.3.4.8 PROCUREMENT, ERECTION & INSTALLATION ................................................... 4139 3.2.3.4.8.1 GENERAL ........................................................................................................................................ 4139 3.2.3.4.8.2 SITE INTEGRATION TEST (SIT)................................................................................................... 4139

3.2.3.4.9 COLD & HOT COMMISSIONING ............................................................................. 4240 3.2.3.4.9.1 COMMISSIONING .......................................................................................................................... 4240 3.2.3.4.9.2 COLD COMMISSIONING............................................................................................................... 4341

3.2.3.4.9.2.1 FUNCTIONAL TESTS................................................................................................................. 4341 3.2.3.4.9.2.2 VALVE AND DAMPER Actuator TESTS................................................................................... 4341 3.2.3.4.9.2.3 ELECTRICAL DRIVE TESTS..................................................................................................... 4341 3.2.3.4.9.2.4 INSTRUMENT CHECKS ............................................................................................................ 4341

3.2.3.4.9.3 HOT COMMISSIONING ................................................................................................................. 4341 3.2.3.4.9.3.1 GENERAL.................................................................................................................................... 4341 3.2.3.4.9.3.2 OPERATIONAL ACCEPTANCE TEST (OAT) .......................................................................... 4442



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3.2.3.4.10 OPTIMISATION STAGE ........................................................................................... 4442 3.2.3.4.10.1 GENERAL ........................................................................................................................................ 4442 3.2.3.4.10.2 CONTROL AND INSTRUMENTATION SYSTEM OPTIMISATION .......................................... 4543 3.2.3.4.10.3 CAPABILITY ACCEPTANCE TEST (cat)...................................................................................... 4543

3.2.3.4.11 “AS BUILT” DOCUMENTATION PACKAGE............................................................. 4543 3.2.3.4.12 SIMULATOR METHODOLOGY................................................................................ 4543

3.2.3.4.12.1 GENERAL ........................................................................................................................................ 4543 3.2.3.4.12.2 SIMULATOR.................................................................................................................................... 4644

3.2.3.4.12.2.1 Simulator Phased Approach ........................................................................................................ 4745 3.2.3.4.12.2.1.1 Simulator– Phase 1 ............................................................................................................. 4745 3.2.3.4.12.2.1.2 Simulator – Phase 2 ............................................................................................................ 4846 3.2.3.4.12.2.1.3 Simulator – Phase 3 ............................................................................................................ 4846 3.2.3.4.12.2.1.4 Simulator – Phase 4 ............................................................................................................ 4846

3.2.3.4.12.2.2 SIMULATOR SYSTEM ENGINEERING ................................................................................. 4846 3.2.3.4.12.2.3 SIMULATOR PRODUCTION ENGINEERING ....................................................................... 4947 3.2.3.4.12.2.4 SIMULATOR SITE INTEGRATION TEST .............................................................................. 4947 3.2.3.4.12.2.5 SIMULATOR UPDATE TO POWER ISLAND 6 ‘AS BUILT’ STATUS................................. 4947 3.2.3.4.12.2.6 SIMULATOR UPDATE TO Station ‘AS BUILT’ STATUS ..................................................... 4947

3.2.3.5 CONTROL AND INSTRUMENTATION SYSTEM REQUIREMENTS................. 5048 3.2.3.5.1 CONTROL AND INSTRUMENTATION SYSTEM PERFORMANCE........................ 5048

3.2.3.5.1.1 LIFE EXPECTANCY ....................................................................................................................... 5048 3.2.3.5.1.2 RELIABILITY .................................................................................................................................. 5048 3.2.3.5.1.3 AVAILABILITY............................................................................................................................... 5149 3.2.3.5.1.4 Performance of the Individual control loops ..................................................................................... 5250 3.2.3.5.1.5 Reliability, Availability and Maintainability (RAM) Studies............................................................ 5250 3.2.3.5.1.6 CONTROL AND INSTRUMENTATION SYSTEM EXPANDABILITY....................................... 5351

3.2.3.5.2 CONTROL AND INSTRUMENTATION SYSTEM STANDARDISATION ................. 5452 3.2.3.5.3 PLANT CONTROL PHILOSOPHY............................................................................ 5553

3.2.3.5.3.1 level of automation............................................................................................................................ 5553 3.2.3.5.3.2 Alarming and Event recording .......................................................................................................... 5654 3.2.3.5.3.3 CONTROL FUNCTIONAL SPECIFICATION................................................................................ 5654 3.2.3.5.3.4 GENERAL DESCRIPTION OF THE SEQUENCE / BINARY CONTROL.................................... 5755

3.2.3.5.3.4.1 Binary Control Sub Systems ......................................................................................................... 5755 3.2.3.5.3.5 GENERAL DESCRIPTION OF ANALOGUE CONTROL ............................................................. 5855

3.2.3.5.3.5.1 Plant Control Modes with Local Control Facilities (LCS & LCP) ............................................... 5855 3.2.3.5.4 CONTROL AND INSTRUMENTATION SYSTEM FUNCTIONS .............................. 5856

3.2.3.5.4.1 GENERAL ........................................................................................................................................ 5856 3.2.3.5.4.2 PROCESS COMMUNICATION BUS SYSTEMS........................................................................... 5957 3.2.3.5.4.3 FUNCTIONAL DISTRIBUTION..................................................................................................... 6058 3.2.3.5.4.4 REDUNDANCY............................................................................................................................... 6058 3.2.3.5.4.5 DATA ACQUISITION ..................................................................................................................... 6159

3.2.3.5.4.5.1 Output Signals............................................................................................................................... 6260 3.2.3.5.4.5.2 Switchgear Capabilities................................................................................................................. 6360 3.2.3.5.4.5.3 Galvanic Isolation ......................................................................................................................... 6361

3.2.3.5.4.6 TIME SYNCHRONISATION........................................................................................................... 6361 3.2.3.5.4.7 BOILER CONTROL AND SAFETY SYSTEM............................................................................... 6462

3.2.3.5.4.7.1 GENERAL.................................................................................................................................... 6462 3.2.3.5.4.7.2 ROLE OF CONTROL IN BOILER SAFETY .............................................................................. 6562 3.2.3.5.4.7.3 BURNER MANAGEMENT SYSTEM ........................................................................................ 6563 3.2.3.5.4.7.4 BOILER PROTECTION SYSTEM.............................................................................................. 6563 3.2.3.5.4.7.5 BOILER tube wall temperature monitoring and boiler lifetime monitor ...................................... 6663

3.2.3.5.4.8 Alarm Management System............................................................................................................... 6664 3.2.3.5.4.9 Asset Management System................................................................................................................ 6664

3.2.3.5.5 CONTROL / ENGINEERING / DIAGNOSTICS / COMMISSIONING ROOMS......... 6765 3.2.3.5.5.1 POWER ISLAND Control Suite (PICS) Facilities ........................................................................... 6765 3.2.3.5.5.2 Balance of Plant Control SUITE (BOPCS) Facilities ....................................................................... 6865 3.2.3.5.5.3 Water Treatment Plant Remote Control Panel (WTPRCP) Facilities ............................................... 6866 3.2.3.5.5.4 Temporary Station control suite and temporary commissioning room (sCs-temp) ........................... 6866 3.2.3.5.5.5 power island 4-6 and EOD Engineering / Diagnostics and Commissioning Room (EDCR4-6) Facilities

6967 3.2.3.5.5.6 power island 1-3 Engineering / Diagnostics and Commissioning Room (EDCR1-3) Facilities........ 7068 3.2.3.5.5.7 TEMPORARY AND PERMANENT CONTROL SUITES, WATER TREATMENT REMOTE

CONTROL PANEL AND TEMPORARY AND PERMANENT EDCR DESIGN REQUIREMENTS..................... 7168 3.2.3.5.5.7.1 pOWER iSLAND cONTROL SUITE (PICS) DESIGN REQUIREMENTS................................ 7270 3.2.3.5.5.7.2 BALANCE OF PLANT CONTROL Suite (BOPCS) DESIGN REQUIREMENTS .................... 7572



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3.2.3.5.5.7.3 Water Treatment Plant Remote Control Panel DESIGN REQUIREMENTS ............................... 7573 3.2.3.5.5.7.4 Permanent ENGINEERING / DIAGNOSTIC / COMMISSIONING ROOMS (EDCR1-3 & EDCR4-

6) DESIGN REQUIREMENTS ............................................................................................................................. 7674 3.2.3.5.5.8 CONTROL rOOMS AND EDCR PRINTING REQUIREMENTS .................................................. 7674

3.2.3.5.5.8.1 GENERAL.................................................................................................................................... 7674 3.2.3.5.5.8.2 PRINTER STANDS...................................................................................................................... 7775

3.2.3.5.6 OPERATOR WORKSTATIONS................................................................................ 7775 3.2.3.5.6.1 GENERAL ........................................................................................................................................ 7775 3.2.3.5.6.2 OPERATOR DATA.......................................................................................................................... 7876 3.2.3.5.6.3 CALCULATED Values (COMPOSED Values) ............................................................................... 7976

3.2.3.5.7 ENGINEERING AND DIAGNOSTIC WORKSTATIONS........................................... 7977 3.2.3.5.7.1 GENERAL ........................................................................................................................................ 7977 3.2.3.5.7.2 DOCUMENTATION MANAGEMENT SYSTEM .......................................................................... 8279

3.2.3.5.8 EQUIPMENT ROOMS .............................................................................................. 8279 3.2.3.5.8.1 Power Island EQUIPMENT ROOMS............................................................................................... 8380 3.2.3.5.8.2 BALANCE OF PLANT EQUIPMENT rooms (including sub-stations) ........................................... 8381

3.2.3.5.9 PLANT INFORMATION SYSTEM............................................................................. 8481 3.2.3.5.9.1 PLANT INFORMATION STORAGE .............................................................................................. 8481 3.2.3.5.9.2 PIS CLIENT INTERFACE ............................................................................................................... 8582 3.2.3.5.9.3 STATION BUSINESS LAN INTERFACE ...................................................................................... 8582 3.2.3.5.9.4 REDUNDANCY............................................................................................................................... 8582 3.2.3.5.9.5 TIME SYNCHRONISATION........................................................................................................... 8583 3.2.3.5.9.6 SECURITY ....................................................................................................................................... 8583 3.2.3.5.9.7 PIS DATABASE STRUCTURE....................................................................................................... 8683 3.2.3.5.9.8 REPORTS ......................................................................................................................................... 8683

3.2.3.5.10 OTHER SYSTEMS AND INTERFACES REQUIREMENTS ..................................... 8784 3.2.3.5.10.1 Firewalls between Control and instrumentation system and Eskom Business LAN.......................... 8784 3.2.3.5.10.2 SOOTBLOWERS ............................................................................................................................. 8784 3.2.3.5.10.3 RADIO TELEMETRY SYSTEM ..................................................................................................... 8785 3.2.3.5.10.4 COMPRESSOR CONTROL AND INSTRUMENTATION SYSTEM ............................................ 8885 3.2.3.5.10.5 PULSE JET FABRIC Filter Plant (PJFFP) SYSTEM ...................................................................... 8885 3.2.3.5.10.6 rotary air pre-heaters ......................................................................................................................... 8885 3.2.3.5.10.7 GENERATOR PROTECTION, AVR & SYNCHRONISER SYSTEM ........................................... 8886 3.2.3.5.10.8 GENERATOR CORE HEALTH MONITORING SYSTEM............................................................ 8986 3.2.3.5.10.9 Boiler Tube Wall Temperature MONITORING SYSTEM............................................................... 8986 3.2.3.5.10.10 GENERATOR FAULT RECORDER ............................................................................................... 8986 3.2.3.5.10.11 H2 PLANT......................................................................................................................................... 8986 3.2.3.5.10.12 N2 PLANT......................................................................................................................................... 8987 3.2.3.5.10.13 FIRE DETECTION AND ALARM ANNUNCIATION SYSTEM (FDAS)..................................... 9087 3.2.3.5.10.14 conveyor long line protection system................................................................................................ 9087 3.2.3.5.10.15 Ash and Coal Stacker and Reclaimer ................................................................................................ 9088 3.2.3.5.10.16 AUTOMATIC VOLTAGE REGULATOR (AVR)........................................................................... 9188 3.2.3.5.10.17 boiler TUBE LEAK DETECTION.................................................................................................... 9188 3.2.3.5.10.18 HV YARD ERTU ............................................................................................................................. 9189 3.2.3.5.10.19 AGC .................................................................................................................................................. 9289 3.2.3.5.10.20 Energy METERING AND DATA acquisition (EMDAS)................................................................. 9390 3.2.3.5.10.21 VIBRATION & condition monitoring and ANALYSIS SYSTEM FOR MT, DRAUGHT GROUPS &

turbine auxiliaries ........................................................................................................................................................ 9491 3.2.3.5.10.22 Expert Systems .................................................................................................................................. 9492

3.2.3.5.10.22.1 Specification for 19” rack mounted computer (PC) .................................................................. 9592 3.2.3.5.10.22.2 Specification for 19” rack mounted Server (with RAID5 3HDD)............................................. 9592

3.2.3.5.11 FIELD EQUIPMENT.................................................................................................. 9795 3.2.3.5.11.1 GENERAL ........................................................................................................................................ 9795 3.2.3.5.11.2 LIMITS OF SUPPLY AND SERVICES (LOSS) ............................................................................. 9795 3.2.3.5.11.3 INPUT/OUTPUT FUNCTION BLOCK DIAGRAMS (IO Blocks) ................................................. 9896 3.2.3.5.11.4 TRANSMITTERS............................................................................................................................. 9896

3.2.3.5.11.4.1 General ........................................................................................................................................ 9896 3.2.3.5.11.4.2 Tapping points and Isolation Valves........................................................................................... 9896 3.2.3.5.11.4.3 Impulse piping ............................................................................................................................ 9896 3.2.3.5.11.4.4 Manifolds .................................................................................................................................... 9997 3.2.3.5.11.4.5 Temperature Transmitters ........................................................................................................... 9997 3.2.3.5.11.4.6 Magnetic FLOW METERS......................................................................................................... 9997

3.2.3.5.11.5 TRANSMITTER RACKS, EQUIPMENT CABINETS & FIELD PANELS.................................... 9997 3.2.3.5.11.6 SWITCHES..................................................................................................................................... 10098 3.2.3.5.11.7 ANALYSERS ................................................................................................................................. 10098



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3.2.3.5.11.8 JUNCTION BOXES ....................................................................................................................... 10098 3.2.3.5.11.9 LOCAL CONTROL PANELS (LCP) ............................................................................................. 10199 3.2.3.5.11.10 LOCAL CONTROL STATIONS (LCS) ......................................................................................... 10199 3.2.3.5.11.11 VALVES......................................................................................................................................... 10199 3.2.3.5.11.12 ACTUATORS ................................................................................................................................. 10199

3.2.3.5.11.12.1 Pneumatic & HYDRAULIC actuators .................................................................................. 102100 3.2.3.5.11.12.2 Electric Actuators CONTROL BEHAVIOUR...................................................................... 103101

3.2.3.5.12 CABLING............................................................................................................... 103101 3.2.3.5.12.1 CABLING SCOPE DEFINITIONS .............................................................................................. 103101 3.2.3.5.12.2 CABLING SCOPE AND REQUIREMENTS............................................................................... 103101 3.2.3.5.12.3 Cable Schedules ............................................................................................................................ 105103 3.2.3.5.12.4 Cable Management System ........................................................................................................... 105103

3.2.3.5.13 EARTHING, LIGHTNING AND ELECTRICAL PROTECTION ............................. 106104 3.2.3.5.14 POWER SUPPLIES .............................................................................................. 106104

3.2.3.5.14.1 GENERAL .................................................................................................................................... 106104 3.2.3.5.14.2 Quality of Supply .......................................................................................................................... 107105

3.2.3.5.14.2.1 Typical quality of supply......................................................................................................... 107105 3.2.3.5.14.2.1.1 Normal AC supply conditions......................................................................................... 107105 3.2.3.5.14.2.1.2 Abnormal AC power supply conditions.......................................................................... 108106

3.2.3.5.14.2.2 Power conditioning ................................................................................................................. 109107 3.2.3.5.14.2.3 Non-linear loads...................................................................................................................... 109107

3.2.3.5.14.3 Power Distribution Concept .......................................................................................................... 109107 3.2.3.5.14.3.1 220 V AC UPS and 24 V DC unitised power systems (Power Island 1 to 6 16 mETER level

auxiliary bay) 109107 3.2.3.5.14.3.2 Station 220 V AC UPS and 24 V DC power systems at Power Island 6 16m level auxiliary bay

110108 3.2.3.5.14.3.3 Station 220 V AC UPS and 24 V DC power systems at Power Island 3 16m level auxiliary bay

110108 3.2.3.5.14.3.4 WTP 220 V AC UPS and 24 V DC power systems at WTP Building .................................... 111109 3.2.3.5.14.3.5 SSB 220 V AC UPS and 24 V DC power systems at SSB Building....................................... 111109 3.2.3.5.14.3.6 Sub-Station 220 V AC UPS and 24 V DC power systems at Balance of Plant....................... 111109

3.2.3.5.14.4 AC AND DC ISOLATION FACILITIES ..................................................................................... 112110 3.2.3.6 SIMULATOR.................................................................................................. 113111

3.2.3.6.1 SIMULATOR USE ................................................................................................. 113111 3.2.3.6.2 SIMULATOR SYSTEM PERFORMANCE............................................................. 114112 3.2.3.6.3 SIMULATOR SCOPE............................................................................................ 114112 3.2.3.6.4 TEMPORARY SIMULATOR SUITE (SS-TEMP) AND PERMANENT SIMULATOR SUITE (SS-PERM)...................................................................................................................... 115113 3.2.3.6.5 SIMULATOR HARDWARE ................................................................................... 115113 3.2.3.6.6 SIMULATOR SOFTWARE AND FUNCTIONALITY ............................................. 116114

3.2.3.6.6.1 Plant Malfunctions ........................................................................................................................ 117115 3.2.3.6.6.2 External Parameters....................................................................................................................... 117115

3.2.3.6.7 SIMULATOR DOCUMENTATION ........................................................................ 117115 3.2.3.6.7.1 Instructor / Maintenance Documentation ...................................................................................... 117115 3.2.3.6.7.2 Software Documentation ............................................................................................................... 118116 3.2.3.6.7.3 Hardware Documentation.............................................................................................................. 118116

3.2.3.6.8 SIMULATOR PERSONNEL TRAINING................................................................ 118116 3.2.3.7 PLANT CODIFICATION AND LABELLING.................................................... 118116 3.2.3.8 DOCUMENTATION AND SOFTWARE CONTROL ....................................... 119117

3.2.3.8.1 GENERAL ............................................................................................................. 119117 3.2.3.8.2 DOCUMENTATION SYNOPSIS ........................................................................... 120118 3.2.3.8.3 OPERATING, MAINTENANCE AND TRAINING MANUALS................................ 120118 3.2.3.8.4 MODIFICATIONS.................................................................................................. 121119 3.2.3.8.5 DOCUMENTATION CONTROL............................................................................ 121119 3.2.3.8.6 PROJECT COMPLETION DOCUMENTATION AND SOFTWARE ..................... 121119

3.2.3.9 CONFIGURATION MANAGEMENT .............................................................. 123121 3.2.3.10 TRAINING ................................................................................................. 124122

3.2.3.10.1 GENERAL ............................................................................................................. 124122 3.2.3.10.2 TRAINING OF ENGINEERING STAFF ................................................................ 124122

3.2.3.10.2.1 Engineering Staff Training Content .............................................................................................. 125123 3.2.3.10.3 TRAINING OF MAINTENANCE STAFF ............................................................... 125123

3.2.3.10.3.1 Maintenance Staff Training Content ............................................................................................. 127125



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3.2.3.10.4 TRAINING OF OPERATORS AND SIMULATOR INSTRUCTORS / ENGINEERING 128126

3.2.3.10.4.1 Operator Training Content ............................................................................................................ 128126 3.2.3.10.4.2 Simulator Instructor / Engineering Content................................................................................... 128126

3.2.3.10.5 TRAINING DOCUMENTATION ............................................................................ 129127 3.2.3.10.6 PARTICIPATION OF EMPLOYER STAFF ........................................................... 130128 3.2.3.10.7 CERTIFICATION OF EMPLOYER STAFF COMPETENCE................................. 130128

3.2.3.11 LICENSES AND CONFIDENTIALITY........................................................ 131129 3.2.3.11.1 LICENSES............................................................................................................. 131129 3.2.3.11.2 UPGRADES .......................................................................................................... 131129

3.2.4 WORKS EQUIPMENT AND SERVICES PROVIDED BY THE ENGINEER ...... 131129

3.2.4.1 FIELD EQUIPMENT FOR ALL PLANT AREAS ............................................. 131129 3.2.4.2 SIGNAL INTERFACES.................................................................................. 131129 3.2.4.3 ELECTRICAL SWITCHGEAR ....................................................................... 132130 3.2.4.4 SWITCHGEAR INTERPOSING RELAYS...................................................... 132130 3.2.4.5 POWER SUPPLIES ...................................................................................... 132130 3.2.4.6 CABLING....................................................................................................... 132130 3.2.4.7 CONTROL ROOMS AND EDCR ................................................................... 133130 3.2.4.8 EQUIPMENT ROOMS & DC POWER SUPPLY ROOMS.............................. 133131 3.2.4.9 TEMPORARY AND PERMANENT SIMULATOR SUITES............................. 133131 3.2.4.10 INFORMATION SYSTEM .......................................................................... 134132

3.2.5 COMPLETION .................................................................................................. 134132

3.2.5.1 WORK TO BE PROVIDED BY THE CONTRACTOR FOR COMPLETION ... 134132 3.2.5.1.1 DESIGN FREEZE ................................................................................................. 134132 3.2.5.1.2 FACTORY ACCEPTANCE TEST (FAT) ............................................................... 134132 3.2.5.1.3 SITE INTEGRATION TEST (SIT) ......................................................................... 134132 3.2.5.1.4 OPERATIONAL ACCEPTANCE TEST (OAT) ...................................................... 134132 3.2.5.1.5 CAPABILITY ACCEPTANCE TEST (CAT) ........................................................... 134132 3.2.5.1.6 POWER ISLAND COMPLETION.......................................................................... 135132 3.2.5.1.7 SIMULATOR ......................................................................................................... 135133

3.2.6 CONTRACTORS ORGANISATION .................................................................. 135133



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INDEX OF FIGURES

FIGURE 1 POWER ISLAND CONTROL AND INSTRUMENTATION SYSTEM 22 FIGURE 2: BALANCE OF PLANT CONTROL AND INSTRUMENTATION SYSTEM 23 FIGURE 3: MEDUPI CONTROL AND INSTRUMENTATION SYSTEM 24 FIGURE 4: MEDUPI PLANT AREA DEFINITIONS 2625 FIGURE 5: OVERALL PROJECT STRUCTURE 3129 FIGURE 6: POWER ISLAND 6 PROJECT METHODOLOGY 3331 FIGURE 7: BALANCE OF PLANT METHODOLOGY 3432 FIGURE 8: SYSTEM ENGINEERING METHODOLOGY 3533 FIGURE 9: SIMULATOR PROJECT METHODOLOGY 4745 FIGURE 10: POWER ISLAND OPERATOR STATION CONFIGURATION 7371 FIGURE 11: EOD OPERATOR STATION CONFIGURATION 7472 FIGURE 12: ENGINEER WORKSTATION CONFIGURATION 8077

INDEX OF TABLES

TABLE 1: POWER ISLAND AREA FUNCTION GROUP DEFINITIONS 2826 TABLE 2: WATER TREATMENT PLANT FUNCTION GROUP DEFINITIONS 2927 TABLE 3: LOW PRESSURE SERVICES FUNCTION GROUP DEFINITIONS 2927 TABLE 4: COAL FUNCTION GROUP DEFINITIONS 2927 TABLE 5: ASH FUNCTION GROUP DEFINITIONS 3028 TABLE 6: OTHER SYSTEMS FUNCTION GROUP DEFINITIONS 3028 TABLE 7: MISCELLANEOUS SYSTEMS FUNCTION GROUP DEFINITIONS 3028 TABLE 8: STANDARD ASDU USED IN IEC60870-5-101 IMPLEMENTATION 9289 TABLE 9: EXPERT SYSTEM COMPUTERS AND CUBICLES 9694 TABLE 10: SCHEDULE OF TRAINED MAINTENANCE STAFF AVAILABLE TO THE ENGINEER 126124

INDEX OF APPENDICES

Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) Appendix 2 – Drive & Actuator Schedule Appendix 3 – Valve Schedule Appendix 4 – Instrument Schedule Appendix 5 – Electrical Reticulation Breaker List Appendix 6 – Panel Interface List Appendix 7 – Virtual Signal List Appendix 8 – Function IO Block Diagrams Appendix 9 – Limits of Supply and Services Appendix 10 – Operating and Control Philosophies Appendix 11 – Medupi Plant Descriptions Appendix 12 – Project Drawings Appendix 13 – Control, Battery and Equipment Rooms Appendix 14 – Project Standards Appendix 15 – Minimum Assessment and Testing Requirements Appendix 16 - Employer Minimum Requirements for Level of Automation Appendix A – Simulator Appendix B – Engineering and FAT Appendix C - C&I System Requirements Appendix D - Time Synchronisation Appendix E - Radio Telemetry



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Appendix F - System Architecture Appendix G - Maintenance Procedures Appendix H - Engineering Procedures Appendix I - SIL Certification Appendix J - Expandability Report Appendix K - Alarm Management System Appendix L - Asset Management System Appendix M - Control Suite Concepts Appendix N - Job Descriptions Appendix O - Energy Management System (EMDAS) Appendix P - Condition Monitoring Appendix Q - Field Instrumentation Data Appendix R - Power Supplies Appendix S - Sample Documentation Appendix T - Plant Information System Appendix U - Interfaces Appendix V - Training schedule



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3.2.1 INTRODUCTION

The objective of the Medupi Power Station Control and Instrumentation Package is to provide an integrated, standardised, highly available and reliable modern control and instrumentation system with field instrumentation and actuation for the complete power station.

Even where instrumentation and control and instrumentation systems are provided by Other Project Contractors the objective remains that the control and instrumentation system and HMI shall be integrated as to present a uniform and standardised front to the operating, maintenance and engineering personnel of the power station.

3.2.1.1 CONTROL AND INSTRUMENTATION DOCUMENTATION STRUCTURE

3.2.1.1.1 SPECIFICATION STRUCTURE AND CONTRACTOR INSTRUCTIONS

The Contractor shall use the C&I documentation as given in the Appendices in conjunction with this Specification.

The relations between the control and instrumentation documentation in the Appendices are as follows:

Appendix 9 – Limits of Supply and ServicesAppendix 9 – Limits of Supply and Services

The scope of supply and services of the Contractor is given in graphical format in the LOSS diagrams. The LOSS diagrams indicate the scope of supply and services for individual items such as instrumentation and the supply and interfaces to stand alone systems. The Contractor shall be responsible to identify scope of supply and services that are not indicated on the LOSS diagrams, and shall be required to ensure a functional control and instrumentation system.

Appendix 4 – Instrument ScheduleAppendix 4 – Instrument Schedule

The field instrumentation that shall be interfaced to the control and instrumentation system as analogue and/or digital input and output are given in the Instrument Schedule. The Contractor shall provide for the scope of supply and services as per the LOSS Diagrams referenced in the Instrument Schedule and the requirements of this Specification.

The Contractor shall use the Instrument Schedule to determine the input/output count for the field instrumentation. Where no Functional IO Block Diagram is referenced in the Instrument Schedule, the Contractor shall assume a single input into the control and instrumentation system of the type identified in the Instrument Schedule. Where a Functional IO Block Diagram is referenced the Contractor shall allow for the number and type of input/output as defined in the Functional IO Block Diagram

Appendix 6 – Panel Interface ListAppendix 6 – Panel Interface List

The Panel Interface List indicates the stand alone systems supplied by Other Project Contractors that the Contractor shall interface to. The detail of the bus and/or hard wired interface is given in the Functional IO Block Diagrams referenced in the Panel Interface List. For the stand alone systems in the Panel Interface List the operating and control



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philosophies are implemented by Other Project Contractors in control hardware provided by Other Project Contractors. For all other systems the Contractor shall implement the operating and control philosophies supplied by Other Project Contractors in the control and instrumentation system supplied by the Contractor. The stacker and reclaimer PLCs specifically are exceptions for though they appear on the Panel Interface List the Contractor shall implement the operating and control philosophy supplied by the Other Project Contractors in the control system supplied by the Contractor.

Appendix 8 – Function IO Block DiagramsAppendix 8 – Function IO Block Diagrams

The Functional IO Block Diagrams details the type and quantity of the inputs and outputs from control and instrumentation equipment. In the case of a bus interface, the Functional IO Block Diagrams are referenced in a Virtual Signal List. The Virtual Signal List gives a detail description of the information that shall be transmitted over the bus. The Contractor shall use the Functional IO Block Diagrams and the requirements of this Specification in order to determine the hard wired and bus input/output requirement for the control and instrumentation system.

Appendix 7 – Virtual Signal ListAppendix 7 – Virtual Signal List

The Virtual Signal List referenced in the Functional IO Block Diagrams gives the detail information on the quantity and signal descriptions of the information that is transmitted over the bus.

Appendix 2 – Drive & Actuator ScheduleAppendix 2 – Drive & Actuator Schedule

The Drive and Actuator Schedule lists all actuators including electrical, pneumatic and solenoids and motor drives and feeders. The contractor shall provide the drives and actuators according to the LOSS Diagrams referenced in the Drive and Actuator Schedule. The Contractor shall use the Functional IO Block Diagram reference to determine the input/output requirements of the control and instrumentation system.

Appendix 3 – Valve ScheduleAppendix 3 – Valve Schedule

The Valve List gives all the Valves forming part of the Works unless otherwise stated. The Contractor shall provide the valves as part of the LOSS.

Appendix 10 – Operating and Control PhilosophiesAppendix 10 – Operating and Control Philosophies and Appendix 11 – Medupi Plant DescriptionsAppendix 11 – Medupi Plant Descriptions

The operating and control philosophies and plant description in Appendix 10Appendix 10 and Appendix 11Appendix 11 are for information purposes only. The Contractor shall provide operating and control philosophies that are acceptable to the Engineer and with documentation as described within the Appendices.

Contractor submitted information is included in the Appendices of 3.2. This inclusion does not relieve the Contractor of his responsibility in meeting the Employer’s Requirements.

3.2.2 SPECIFIC ABBREVIATIONS AND DEFINITIONS

3.2.2.1 ABBREVIATIONS

AGC Automatic Generation Control



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AKZ Power Plant Coding System

ASDU Application service data unit AU Automation Unit AP Automation Processor

AuxGC Auxiliary Group Control AVC Automatic Voltage Controller

AVR Automatic Voltage Regulator BME Bandwidth Management Equipment BMS Burner Management System

BOP Balance of Plant BOPCS Balance of Plant Control Suite

BPS Boiler Protection System CAT Capability Acceptance Test C&I Control and Instrumentation

CSC Control System Automation Units, Controllers, Cubicles and Associated Equipment (Infrastructure)

CS-COM/BUS Control System Communication Bus Systems between HMI Workstations and Control Cubicles (Infrastructure)

CS-I/O Control System (Functional Block Inputs / Outputs) CSV Comma-separated variable

CPP Condensate Polishing Plant CPS Corrosion Product Sampling

CTBOP Cable Trenching for Balance of Plant DCS Distributed Control and instrumentation system referred to

as only control and instrumentation system in this Specification.

DHP Dust Handling Plant DMS Document Management System EDCR Engineering /Diagnostic/Commissioning Room

EFP Electric Feed Pump ENGSE Specialist Engineering and Commissioning

EOD Electrical Operating Desk ERTU Enhanced Remote Terminal Unit ESV Emergency Stop Valves

FAT Factory Acceptance Test FE-LOSS Field Equipment – Limits of Supply and Services

FG Function Group FM Frequency Modulation FMECA Failure Mode Effects and Criticality Analysis

GC Group control HDD Hard Disk Drive

HMI Human Machine Interface HTML Hyper Text Mark-up Language HVAC Heating, Ventilation and Air Conditioning

I/O Input/Output iBMS Integrated Building Management System

IDC Individual drive control I&TP Inspection and Test Plan KKS Kraftwerk Kennzeichen System, Power Plant Coding

System LAN Local Area Network

LCO Local Control Officer



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LCS Local Control Station with hardwired interface to the control and instrumentation system

LCP Local Control Panel with bus interface to the control and instrumentation system

LOSS Limits Of Supply and Services

LPS Low Pressure Services LV Low Voltage < 1 000 V AC mA milliampere

Mbps Megabits per second MTTF Mean Time To Failure

MV Medium Voltage > 1 000 V AC MCR Maximum Capability Rating NCC National Control Centre

NER/NERSA National Energy Regulator (South Africa) NIC Network Interface Card

NPSH Net Positive Suction Head OAT Operational Acceptance Test OBMS Oil Burner Management System

ODBC Open Database Connectivity Other Project Contractor Original Equipment Manufacturer

OHSA Occupational Health and Safety Act OPC Object Linking and Embedding for Process Control ORP Oxidation Reduction Potential

PC Personal Computer PI Power Island

PIS Plant Information System PJFFP Pulse Jet Fabric Filter Plant PFA Pulverised Fly Ash

PLC Programmable Logic Controller PS Power Station

PSD-LOSS Power Supply and Distribution equipment – Limits of Supply and Services

QAP Quality Assurance Programme QC Quality Control QMP Quality Management Programme

RDBMS Relational Data Base Management System RTD Resistance Temperature Detector

SIT Site Integration Test PICS Power Island Control Suite SER Station Electrical Reticulation

SCS-TEMP Temporary Station control suite and temporary commissioning room

SGC Sub-group control SQL Structured Query Language

SOE Sequence of Events SOV Solenoid Operated Valve

SSC Submersed Scraper Conveyor SSS Station Shift Supervisor SS-PERM Permanent Simulator Suite

SS-TEMP Temporary Simulator Suite TC Thermocouple

TCECR Trunk Cabling excluding Cable Racks (Multi-core cabling between field junction box and cubicles and between



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cubicles)

TCP/IP Transmission Control Protocol / Internet Protocol TCR Trunk Cable Racks (for multicore cabling) TCU Temperature Control Unit

TOC Total Organic Carbon TRAIN Training

UER Power Island Electrical Reticulation UPS Uninterruptible Power Supply URS User Requirement Specification

VI Voltage – Current characteristic WTP Water Treatment Plant

WTPRCP Water Treatment Plant Remote Control Panel

3.2.2.2 DEFINITIONS

Sections of plant

Auxiliary plant (Balance of Plant)

In this Specification all plant and systems producing services to the major plant (Power Islands)

Equipment Plant and Material

LPS Low Pressure Services including compressed air, auxiliary cooling, fuel oil storage and offloading, potable water distribution, raw water supply, fire water distribution etc.

Major plant Machinery e.g. feed pumps, turbine, mill, air heater, fans etc. Balance of Plant All plant and equipment that does not fall under the Power Island

areas, including the station electrical reticulation, LPS, WTP, Coal & Ash.

Specification The document/s forming part of the contract in which are described the methods of executing the various items of work to be done, and the nature and quality of the materials to be supplied and includes technical schedules and drawings attached thereto as well as all samples and patterns

Station Business LAN

Station-wide Local Area Network for access by the wider Medupi Power Station staff

Plant Area The plant areas are the six Power Island Areas and Balance of Plant Area.

Power Island / Unit Boiler, Turbine, Generator, cooling system, Pulse Jet Fabric Filter plant and including all auxiliary plant and systems associated with the Power Island, including the Power Island electrical reticulation

Control and Instrumentation System

Application Software

Custom designed software for Medupi Power Station that includes but is not limited to a) Binary and Analog control of all processes in the scope b) Bus and gateway Interface data configuration to 3rd party and

expert systems c) Expert system interface configurations d) Medupi Specific field designs e) PIS configuration and templates developed for PIS f) HMI screens

System Software Generic OEM off-the-shelf software used to produce Medupi specific software which includes but is not limited to a) Operating system software, b) Engineering tools for DCS and all equipment or interfaces in

scope



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c) Field Equipment Engineering tools d) Bus and gateway Interfaces system configuration e) Time synchronisation configuration f) Wireless equipment configuration and Medupi specific

programmes g) Network configuration

Automation unit Integrated control unit with input/output capabilities, redundant power supplies and intelligent redundant automation processors

Automation processor

Intelligent processing unit used for all digital calculations

Control Elements This includes all inline devices associated with the plant process, e.g. valves, dampers, primary elements etc.

Medupi control and instrumentation system

The control and instrumentation system consists of all field equipment, control equipment, communication networks, process computers and software provided by the Contractor.

Balance of Plant control and instrumentation System

The portion of the control and instrumentation system specific to the Balance of Plant also known as Balance of Plant

Power Island control and instrumentation System

The portion of the control and instrumentation system specific to a particular Power Island also known as the Power Island

Drives Drives are all mechanical or electrical prime movers, e.g. actuators, pumps, fans, etc.

Expert System Computer based system used for high computational power required functions

Engineering and Diagnostic Workstation

Dedicated engineering & diagnostic facilities for the applicable plant area with the specified number of operating display units and pointing devices also known as Engineering, Diagnostic and Commissioning workstation

Field Equipment All field control and measurement equipment and associated installation equipment i.e. Transmitters, Switches, Analysers, Actuators, Valves, Junction Boxes, Splitter Boxes, Field Cabling, Secondary Racking, Conduits, Local Control Stations, Cables, Transmitter Racks, Field Panels, Equipment Cabinets and equipment as defined in the LOSS diagrams in Appendix 9

Information display unit

46 inch LCD flat screen with a minimum resolution of 1920 x 1080 also known as large screen displays

Local Control Station

Local Control Stations are remote operator stations located in the field with a hardwired interface to the control and instrumentation system.

Local Control Panel Local Control Panels are remote operator stations located in the field. The LCPs interface to the control and instrumentation system through the process communication bus

Operating and Engineering display unit

21 inch LCD flat screen with a minimum resolution of 1600 x 1200

Operator and Engineering display processor

All computer hardware required to accept operator inputs via keyboard and mouse and drive the required number of operator display units.

Operator Workstation

Operating and monitoring facilities for the applicable plant area with the specified number of operating display units, pointing devices and allowing the specified number of independent



PAGE 14 OF 133133

operations as per Figure 10

Process Computer Any computer, workstation or server supplied by the Contractor EOD workstation Operating and monitoring facilities for the station electrical

reticulation system with the specified number of operating display units, pointing devices and allowing the specified number of independent operations as per Figure 11

Engineering Workstation

Engineering and diagnostic facilities for the control and instrumentation system with the specified number of operating display units, pointing devices and allowing the specified number of independent operations as per Figure 12

System Clock Synchronized from the 50Hz Electricity Grid Master Clock Synchronized from the GPS Differential Clock Difference between the System and Master Clock

Keyboard South African key set QWERTY keyboard with numeric keypad and dust protection used as text input device for all workstations.

Plant Information System

Alarm Event The entry or exit of an analogue or binary signal into or from an alarm or abnormal condition

Binary Event The change of state of a binary signal Entry Alarm Event The entry of an analogue or binary signal into an alarm condition

Exit Alarm Event The exit of an analogue or binary signal from an alarm condition Hot-swappable The capability of being able to disconnect and connect devices

while the computer or other device is in operation, energised, and have those devices detected without having to boot the computer or device.

Near Real-time Data

Data that is updated on a display within 30 seconds of a change in its value

Operator Event An operator action (such as, an on/off command, or a setpoint change etc.)

PIS Client A computer on the Station LAN, which is using the Microsoft Windows XP or later operating system and any process computer on the process communication bus

PIS Database The databases on the PIS Data Servers that store the plant information

PIS Data Servers The servers that store the historical plant information for Medupi Power Station

Plant Information Include tags from all the Units and the Balance of Plant.

Tag An analogue signal, binary signal or an event originating from field devices and/or created by the control and instrumentation system such as calculated values.

Report A formal and structured summary of a sub-set of information produced or stored in the control and instrumentation system

Tag Name An alphanumeric code, KKS code, that is unique to a tag Trend A trend is an X-Y plot in which the horizontal axis is time, and the

vertical axis is a tag value

Simulator

Simulator Models All process models forming part of the Simulator including all plant and control models.

Integrated Building Management System (iBMS)

Integrated Building Management System (iBMS)

An Integrated Building Management System is a single, cohesive building management system controlling:

• Luminescence



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• Emergency lighting

• HVAC

• Fire and smoke detection

• Gas Levels

• Security

• CCTV Security Surveillance

• CCTV process monitoring

• Access control (time and attendance and info options)

• Consumption measurements of water, electricity and cooling (heating) energy

• Perimeter Control

• Asset tracking

Building Management System

A Building Management System is a subsystem of Integrated Building Management System and controls:

• Luminescence

• Consumption measurements of water, electricity and cooling (heating) energy

• HVAC

• Emergency lighting

• Security

Human Machine Interface

Control Suite A suite of rooms fulfilling a number of functions and having facilities for the operating of a number of plant areas. Facilities shall include for example a kitchen, smokers’ room, ablutions, pause areas, operator desks, printing facilities, filing facilities, lockers, offices and meeting rooms.

Control Room Rooms dedicated to the operating function of one or more plant areas.

Zippel Documentation and file modular storage device / assembling bays (frames) on movable bases which run on floor rails. The device has 5 high density storage movable upright bins which are enclosed and lockable



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3.2.3 WORK TO BE PERFORMED AND EQUIPMENT AND PLANT TO BE

PROVIDED BY THE CONTRACTOR FOR THE WORKS

The scope of supply by the Contractor shall include the following:

1. Design, engineering, procurement, manufacture, works testing including Factory Acceptance Testing (FAT), packing, delivery to site, site testing and commissioning of the complete, integrated control and instrumentation for the power plant as described in this specification.

2. All work, equipment and studies such as ergonomic and work flow studies for the Power Plant Operator’s control room facilities including but not limited to:

a. Power Island Control Suite (refer to Clause 3.2.3.5.5.1)

b. Balance of Plant Control Suite (refer to Clause 3.2.3.5.5.3)

c. Water Treatment Plant Remote Operator Suite ((refer to Clause 3.2.3.5.5.3)

d. Power Island 4 to 6 and Electrical Operator’s Desk Temporary Commissioning Control Suite SCS-TEMP (refer to Clause 3.2.3.5.5.4)

e. Power Island 4-6 and Electrical Operator’s Desk engineering / diagnostics and commissioning room (EDCR4-6) facilities (refer to Clause 3.2.3.5.5.5)

f. Power Island 1-3 Engineering / Diagnostics and Commissioning Room (EDCR1-3) facilities (refer to Clause 3.2.3.5.5.6)

g. Engineering Workstation (refer to Clause 3.2.3.5.5.1 to 3.2.3.5.5.6 and 3.2.3.5.7)

h. Temporary and Permanent Simulator Suites (refer to Clause 3.2.3.6.4)

3. Cabling, cablings supports and associated infrastructure as specified in Section 3.2.3.5.12 of this Specification

4. Field Equipment as specified in Section 3.2.3.5.11 of this Specification

5. Vibration Monitoring and Analysis System for condition monitoring as specified in Section 3.2.3.5.10.21 of this Specification

6. Interfacing to Expert Systems as specified in Section 3.2.3.5.10.22 of this Specification

7. Power Supplies and Power Distribution including internal distribution between cubicles as specified in Section 3.2.3.5.14 of this Specification

8. Interfaces to 3rd party systems as specified in 3.2.3.5.10

9. Power Plant Simulator as specified in Section 3.2.3.6 of this Specification

10. Plant Information System as specified in Section 3.2.3.5.9 of this Specification

11. Alarm Management System as specified in Section 3.2.3.5.4.8 of this Specification

12. Asset Management System as specified in Section 3.2.3.5.4.9 of this Specification

13. Document Management System as specified in Section 3.2.3.5.7.2 of this Specification

14. Interfacing to electrical equipment



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15. Plant codification and labelling of equipment supplied as specified in Section 3.2.3.7of this Specification

16. Earthing as specified in Section 3.2.3.5.13 of this Specification

17. Training for Operator, Engineering, Maintenance & Simulator Personnel as specified in Section 3.2.3.10 of this Specification

18. Testing, commissioning and optimisation as specified in Section 3.2.3.4 of this Specification

19. Reliability, Availability and Maintainability (RAM) studies and Failure Mode Effects and Criticality Analysis (FMECA) for all major areas of plant in accordance with Clause 3.2.3.5.1.5 of the specification

20. All activities, services or equipment specified in this Specification (special tools, consumables etc)

21. Software, license and copyright agreements

22. All control and instrumentation equipment which is required in order to fulfil all the functions specified in this Specification, but which is not specifically covered by this Specification

All components form an integrated, working system that ensures the required safety, reliability and operability of the plant, and performs all modulating control, binary control, safety and supervisory functions as detailed in this Specification.

OEM COMMITMENT AND SUPPORT REQUIREMENTS

The objective is to ensure full ownership of the design, engineering, technology selection and integration of the main control system for Medupi Power Station by the International OEM provider of the product. In this way the risk of non-performance of the Control and Instrumentation, and subsequent detrimental impact on the whole plant can be significantly reduced.

This commitment shall be demonstrated in the following way, with specific relevance to the first power Island, however certain aspects are relevant untill Time for Completion;

• OEM assigns a specific Eskom Account Manager for the duration of the project who will take overall accountability for all the aspects identified below, and provide the conduit for communication between the OEM and the Employer.

• OEM to ensure the use of their state of the art standard best practice company internal recommendations and QA requirements within all the project-specific designs – this includes hardware selection and configuration, network configuration, software development, engineering processes, installation practices, commissioning practices and optimisation practices.

• OEM to review in depth and sign off the main project-specific product design concepts and configuration philosophy for the following;

o functional distribution concept, o hardware configuration, o network concepts, o power distribution concepts, o redundancy concepts, o earthing concepts,



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o overall system configuration, o plant information system, o simulator configuration o subcontractors QA compliance

• OEM to review and sign off the main application solution concepts for specific complex control philosophies such as

o Electrical reticulation control, o Water chemistry control, o Unit co-ordinator, o Boiler master controls, o Unit operating modes (sliding pressure, boiler follow, turbine follow,

condensate stop)

• OEM reviews the local representatives Medupi overall project program, and provides assurance that it will ensure all key dates and performance requirements can be met. Additionally, OEM confirms the program includes all relevant key activities required for procurement, system engineering, production engineering, implementation, and testing as per best practice QA processes.

• OEM to ensure the use of latest advanced control strategies (e.g. unit co-ordinator / startup temperature and pressure formation / SH and RH steam temp control / enthalpy control / runback control / combustion optimisation etc)

• OEM to confirm that the configurations are standard according to their international best practice guidelines and that no Medupi specific configurations have been implemented.

• OEM to commit to ensure immediate corrective action response by the appropriate level of specialised skill to any non-performance arising from project-specific design, engineering and product (hardware and software) performance problems during testing, implementation, commissioning and operation of the system.

• OEM to ensure all documentation provided as part of the Medupi C&I contract is comprehensive and conforms with their own internal best practice QA requirements including conformance to Project Standard VGB R170C.

• OEM to provide and perform a comprehensive review of all the test procedures (FAT, SIT, SAT, etc) as well as to confirm acceptance of the results at the end of the tests

• OEM to confirm verification of full functionality of all software interfaces (e.g. OPC, Profibus, Modbus, etc) to other systems prior to installation.

• OEM identifies to the Engineer any significant risks and concerns during the Project execution period that are related to the whole control and instrumentation system. These include aspects where their proposed best practices is in conflict with the Employers Requirements. Where applicable, the OEM recommends appropriate solutions.

• OEM identifies to the Employer any new technologies, control concepts, software applications and other solutions that could improve the overall Medupi performance, and reduce cost of ownership both in the short and long term.



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3.2.3.1 OVERALL SYSTEM TECHNICAL REQUIREMENTS

The Work shall include an integrated control and operating platform and instrumentation for the complete Medupi Power Station Balance of Plant, Boilers, Turbine Auxiliaries and interfaces to the Turbine Control and Instrumentation system.

The Contractor shall provide all equipment and services and execute all work necessary to fulfil all the requirements specified. The Medupi control and instrumentation system shall be configured as a fully operational system and is workable in all aspects and implemented in a consistent and integrated manner. The Medupi control and instrumentation system shall provide all information, protection, process interlocking, control and local control facilities to enable the operator to execute his tasks safely, reliably and consistently.

The Works shall comply with professional engineering practice and standards for super critical fossil fuel power plants, and shall be designed for the environmental conditions prevailing at Medupi Power Station.

The detailed scope of supply for the works shall be defined by a combination of performance, functional and equipment specifications such that a complete functioning system shall be provided.

The basis for the supply of all engineering deliverables shall be in the form of documentation relevant to the different activities as stated in:

• Appendix 1 – Vendor Documentation Submittal Schedule (VDSS)

The Contractor shall submit the documents as indicated with a “C” in a green block during the Project Methodology Phase. The Contractor shall manage, update and keep the documentation during the Project Methodology Phase as indicated by a green block.

The equipment requirements are defined in the following documents:

• Appendix 2 – Drive & Actuator Schedule

• Appendix 3 – Valve Schedule

• Appendix 4 – Instrument Schedule

• Appendix 5 – Electrical Reticulation Breaker List

• Appendix 6 – Panel Interface List

• Appendix 7 – Virtual Signal List

• Appendix 8 – Function IO Block Diagrams

• Appendix 9 – Limits of Supply and Services

• Appendix 12 – Project Drawings

• Appendix 14 – Project StandardsAppendix 14 – Project Standards

• This Specification

The functional requirements are defined in the following documents:

• Appendix 10 – Operating and Control Philosophies

• Appendix 11 – Medupi Plant Descriptions




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The Medupi control and instrumentation system performance is described in the:


The plant performance requirements are described in the following documents:


• Appendix 15 – Minimum Assessment and Testing Requirements

The Limits of Supply and Services are defined in the document:


The Medupi control and instrumentation system shall be designed to fulfil all functions to meet the process plant performance requirements within the constraints of the mechanical plant as provided by the Employer in Appendix 15.

P&IDs provided in Appendix 12 – Project Drawings are preliminary and should not be used in comparison with Appendix 2 – Drive & Actuator Schedule and Appendix 4 – Instrument Schedule. The P&ID can be used as indicative information to describe the processes and to assess the number of control loops and possible mimic screens required for the HMI.

3.2.3.2 PROJECT STANDARDS

The project standard specifications applicable to the Works are listed in Appendix 14 – Project Standards.

The Contractor shall obtain copies of International and National standards documents. The Engineer’s standards documents are provided in Appendix 14 – Project Standards.

The Contractor shall report any conflict within this Specification with any referenced standards, specifications or technical guideline.

This specification shall take preference over the standards in Appendix 14 – Project Standards except for statutory requirements.

Substitutions of any standards in Appendix 14 shall be approved by the Engineer. Additional standards proposed by the Contractor shall be submitted for approval by the Engineer.

3.2.3.3 CONTROL AND INSTRUMENTATION ARCHITECTURE

Appendix F includes example drawings that depict the conceptual system architecture and database architecture. Further architecture definition and complete design shall be executed during project detailed engineering by the Contractor.

3.2.3.3.1 CONTROL AND INSTRUMENTATION SYSTEM BREAKDOWN

Medupi Power Station shall be divided into the following distinct control and instrumentation Systems:

• Six Power Island control and instrumentation systems

• Balance of Plant control and instrumentation system



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The Power Island control and instrumentation System is depicted in Figure 1 and consists of the field instrumentation, control equipment, power supplies and interfaces to third party controls systems, expert systems and HMI equipment for the control, operation, monitoring and engineering of the Power Island concerned.

Each of the six Power Island control and instrumentation systems shall be autonomous in all aspects and shall not have any control and instrumentation equipment common to another Power Island Plant control and instrumentation System. The only exception to this concept is EFG02. The EFG02 I/O for the Power Island concerned shall be contained in that Power Islands C&I System. However, the EFG02 from all the Power Island areas shall be monitored and operated from the EOD as shown in Figure 3 and Figure 4.

Any control and instrumentation equipment that is common between Power Island plant control and instrumentation systems shall be incorporated in the Balance of Plant control and instrumentation system.

The Balance of Plant control and instrumentation system is depicted in Figure 2 and consists of a fully self-contained and independent system that includes the field instrumentation, control equipment, power supplies and interfaces to third party controls systems and expert systems and HMI for the control, operation, monitoring and engineering of the Balance of Plant.



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POWER ISLAND C&I SYSTEM

FIELD EQUIPMENT(Field Devices, Field Cabling, Local Control

Stations & Junction Boxes)

CONTROL SYSTEM CUBICLESController Cabinets

I/O Cabinets, PLCs, etc…)

HMI(Operator Workstations, Engineering

Workstations, Control system Servers)

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SS

OC

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AS

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ack

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itches,

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POWER SUPPLIES

(UPS & DC Power Supplies)

3rd PARTY SYSTEMS

(Turbo-Generator Control & Protection System)

POWER ISLAND EXPERT

SYSTEMS(Furnace

Cleaning, Plant Health Monitor)

Figure 1 Power Island control and instrumentation System



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BALANCE OF PLANT PLANT C&I SYSTEM

FIELD EQUIPMENT(Field Devices, Field Cabling, Local Control

Stations & Junction Boxes)

CONTROL SYSTEM CUBICLESController Cabinets

I/O Cabinets, PLC, etc…)

HMI(Operator Workstations, Engineering

Workstations, Control system Servers)

CA

BLIN

G &

ASSO

CIA

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FRA

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(R

acki

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ork

Sw

itches,

etc

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POWER SUPPLIES

(UPS & DC Power Supplies)

3rd PARTY SYSTEMS

BALANCE OF PLANT EXPERT

SYSTEMS(Coal Blending)

Figure 2: Balance of Plant control and instrumentation System

The six Power Island control and instrumentation systems and the Balance of plant instrumentation and control and instrumentation system are combined to form the Medupi control and instrumentation system as depicted in Figure 3. The Medupi control and instrumentation system shall further include subsystems that are common to the Power Island and Balance of Plant such as the PIS, asset management system and centralised expert systems.

The Medupi control and instrumentation system shall be integrated on an information level. Information from all plant areas in the Power Islands and the Balance of Plant areas shall be available to all Power Islands and the Balance of Plant operators at all Operator Stations. Information for the purpose of control and interlocking shall be available between a Power Island control system and the Balance of Plant control system.



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MEDUPI C&I SYSTEM

PLANT INFORMATION SYSTEM

ASSET MANAGEMENT SYSTEM

CENTRALISED EXPERT SYSTEMS

PI 1 C&I SYSTEM

FIELD EQUIPMENT

CONTROL SYSTEM

CUBICLES

HMI

CA

BL

ING

& A

SS

OC

IAT

ED

IN

FR

AS

TR

UC

TU

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POWER

SUPPLIES

3rd

PARTY

SYSTEM

S

PI 2 C&I SYSTEM

FIELD EQUIPMENT

CONTROL SYSTEM

CUBICLES

HMI

CA

BL

ING

& A

SS

OC

IAT

ED

IN

FR

AS

TR

UC

TU

RE

POWER

SUPPLIES

3rd

PARTY

SYSTEM

S

PI 3 C&I SYSTEM

FIELD EQUIPMENT

CONTROL SYSTEM

CUBICLES

HMI

CA

BL

ING

& A

SS

OC

IAT

ED

IN

FR

AS

TR

UC

TU

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POWER

SUPPLIES

3rd

PARTY

SYSTEM

S

PI 4 C&I SYSTEM

FIELD EQUIPMENT

CONTROL SYSTEM

CUBICLES

HMI

CA

BL

ING

& A

SS

OC

IAT

ED

IN

FR

AS

TR

UC

TU

RE

POWER

SUPPLIES

3rd

PARTY

SYSTEM

S

PI 5 C&I SYSTEM

FIELD EQUIPMENT

CONTROL SYSTEM

CUBICLES

HMI

CA

BL

ING

& A

SS

OC

IAT

ED

IN

FR

AS

TR

UC

TU

RE

POWER

SUPPLIES

3rd

PARTY

SYSTEM

S

PI 6 C&I SYSTEM

FIELD EQUIPMENT

CONTROL SYSTEM

CUBICLES

HMI

CA

BL

ING

& A

SS

OC

IAT

ED

IN

FR

AS

TR

UC

TU

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POWER

SUPPLIES

3rd

PARTY

SYSTEM

S

BOP C&I SYSTEM

FIELD EQUIPMENT

CONTROL SYSTEM

CUBICLES

HMI

CA

BL

ING

& A

SS

OC

IAT

ED

IN

FR

AS

TR

UC

TU

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POWER

SUPPLIES

3rd

PARTY

SYSTEM

S

EXPERT

SYSTEMS

EXPERT

SYSTEMS

EXPERT

SYSTEMS

EXPERT

SYSTEMS

EXPERT

SYSTEMS

EXPERT

SYSTEMS

SER HMI(EOD)

Figure 3: Medupi control and instrumentation System

3.2.3.3.2 CONTROL AND INSTRUMENTATION FUNCTION GROUP

BREAKDOWN

The control and instrumentation Systems shall further be divided into Function Groups (as shown in Figure 4) and



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Table 1Table 1, Table 2, Table 3, Table 4,

Table 5Table 5, Table 6 and Table 7 for the purpose of managing and directing the engineering activities throughout the Works.

The information supplied in this Specification in Appendix 2 to Appendix 13 is in groupings of function groups called sub-systems denoted by SS followed by a numeric identifier. The relation between the sub-systems and the function groups are given in Table 1 to Table 7.

The Contractor shall do the final functional group assignment of the information. The Contractor shall base his design and RAM calculations on the control and instrumentation system architecture and function group breakdown at design freeze.

The Contractor shall during Systems Engineering and Production Engineering optimise on the number of Automation Units used in the control and instrumentation architecture in order to implement the functional group distribution.

The Contractor shall during Systems Engineering and Production Engineering optimise the number of input/output cubicles used in the control and instrumentation architecture in order to implement the functional group distribution.

The Contractor shall during Systems Engineering and Production Engineering optimise the number of UPS and 24 V DC power supply/rectifier cubicles in the substations used in the control and instrumentation architecture taking into consideration the redundancy requirements and functional group distribution.



PAGE 26 OF 134133

Medupi Power Station Plant Area Definition

PI 1 Balance of Plant

Water

Treatment

Plant

LPS

Plant

Coal &

Ash

SER

UFG01

UFG02

UFG03

UFG04

UFG04

UFG05

UFG06

UFG07

UFG08

UFG09

UFG10

UFG11

UFG12

UFG13

UFG14

UFG15

UFG16

UFG17

UFG18

UFG19

UFG20

UFG21

UFG22

UFG23

UFG24

UFG25

UFG26

UFG27

UFG28

UFG29

UFG30

UFG31

UFG32

UFG33

UFG34

EFG02

WFG01WFG02WFG03

WFG04WFG04WFG05

WFG06WFG07

WFG08WFG09WFG10

WFG11WFG12WFG13

WFG14

LFG01LFG02LFG03

LFG04LFG05LFG06

LFG07LFG08

LFG09LFG10LFG11

LFG12LFG13LFG14

LFG15LFG16LFG17

LFG18LFG19

CFG01CFG02CFG03

CFG04AFG01AFG02

AFG03AFG04

AFG05AFG06

EFG01

PI 1 Operator

Station

PI 2

UFG01

UFG02

UFG03

UFG04

UFG04

UFG05

UFG06

UFG07

UFG08

UFG09

UFG10

UFG11

UFG12

UFG13

UFG14

UFG15

UFG16

UFG17

UFG18

UFG19

UFG20

UFG21

UFG22

UFG23

UFG24

UFG25

UFG26

UFG27

UFG28

UFG29

UFG30

UFG31

UFG32

UFG33

UFG34

EFG02

PI 3

UFG01

UFG02

UFG03

UFG04

UFG04

UFG05

UFG06

UFG07

UFG08

UFG09

UFG10

UFG11

UFG12

UFG13

UFG14

UFG15

UFG16

UFG17

UFG18

UFG19

UFG20

UFG21

UFG22

UFG23

UFG24

UFG25

UFG26

UFG27

UFG28

UFG29

UFG30

UFG31

UFG32

UFG33

UFG34

PI 4

UFG01

UFG02

UFG03

UFG04

UFG04

UFG05

UFG06

UFG07

UFG08

UFG09

UFG10

UFG11

UFG12

UFG13

UFG14

UFG15

UFG16

UFG17

UFG18

UFG19

UFG20

UFG21

UFG22

UFG23

UFG24

UFG25

UFG26

UFG27

UFG28

UFG29

UFG30

UFG31

UFG32

UFG33

UFG34

UFG01

UFG02

UFG03

UFG04

UFG04

UFG05

UFG06

UFG07

UFG08

UFG09

UFG10

UFG11

UFG12

UFG13

UFG14

UFG15

UFG16

UFG17

UFG18

UFG19

UFG20

UFG21

UFG22

UFG23

UFG24

UFG25

UFG26

UFG27

UFG28

UFG29

UFG30

UFG31

UFG32

UFG33

UFG34

PI 5 PI 6

UFG01

UFG02

UFG03

UFG04

UFG04

UFG05

UFG06

UFG07

UFG08

UFG09

UFG10

UFG11

UFG12

UFG13

UFG14

UFG15

UFG16

UFG17

UFG18

UFG19

UFG20

UFG21

UFG22

UFG23

UFG24

UFG25

UFG26

UFG27

UFG28

UFG29

UFG30

UFG31

UFG32

UFG33

UFG34

EFG02 EFG02 EFG02 EFG02

PI 2 Operator

Station

PI 3 Operator

Station

PI 4 Operator

Station

PI 5 Operator

Station

PI 6 Operator

Station

WTP Remote Operator

Station

Balance of Plant Plant Operator

Station

EOD Operator Station

Other

OFG01OFG02OFG03

OFG04OFG05

Figure 4: Medupi Plant Area Definitions

3.2.3.3.2.1 POWER ISLAND CONTROL AND INSTRUMENTATION SYSTEM

There are six Power Island areas at Medupi Power Station. Each Power Island area consists of a Boiler/Turbine/Generator/ACC/PJFFP/CPP set and associated auxiliaries. This includes the Power Island electrical reticulation systems (Function Group EFG02). The plant areas and processes that make up the Power Island control and instrumentation system are further divided into function groups as listed in



PAGE 27 OF 135133

Table 1Table 1 below.



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Table 1: Power Island Area Function Group Definitions

UFG01 SS26 Boiler Protection

UFG02 SS36 Turbine Control & Protection

UFG03 SS27 Unit Co-ordinator

UFG04 SS29 Mill 1

UFG05 SS29 Mill 2

UFG06 SS29 Mill 3

UFG07 SS29 Mill 4

UFG08 SS29 Mill 5

UFG09 SS28 Unitised Fuel Oil and Gas Plant

UFG10 SS44 Superheater

UFG11 SS45 Reheater

UFG12 SS30 Draught Group 1

UFG13 SS30 Draught Group 2

UFG14 SS40 Unitised Condensate + Condensate Polishing Plant (CPP)

UFG15 SS38 Feedwater 1



UFG18 SS46 Feed Heaters (LP / HP)

UFG19 SS31 Sootblower Expert Systems (Steam + Water Cannons)

UFG20 SS32 Steam Generation

UFG21 SS41 Boiler Auxiliaries

UFG22 Turbine Auxiliaries

UFG23 SS33 Unit Auxiliaries

UFG24 SS37 Generator and Auxiliaries

UFG25 Dust Conveying System

UFG26 SS50 Bottom Ash Removal System (SSC)

UFG27A SS39 Flue Gas Cleaning (Fabric Filter Plant) A

UFG27B SS39 Flue Gas Cleaning (Fabric Filter Plant) B

UFG28 SS41 Unit Compressors Plant

UFG29 SS49 Ash Conveyor Belt Washing

UFG30 SS42 Analysers Units

UFG31 SS44/ 45 Spraywater Systems

UFG32 SS38 Air Cooled Condensors (ACC)

UFG33 Unit HMI

UFG34 SS1 / 8 Electrical Operator Desk (HMI for UER and HV-Yard)

EFG02 Unit Electrical Reticulation (UER)

3.2.3.3.2.2 BALANCE OF PLANT CONTROL AND INSTRUMENTATION SYSTEM

The Balance of Plant control and instrumentation System consists of all non-Power Island plant and equipment. This includes the station electrical reticulation systems. The Balance of Plant Area is further divided in the following sub-sections as shown in Figure 4 above:

• WTP

• LPS

• Coal

• Ash

• Other Systems

• Station Electrical Reticulation



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Each of the sub-sections is sub-divided into Function Groups as listed in Table 2, Table 3, Table 4,

Table 5Table 5 and Table 6 below.

Table 2: Water Treatment Plant Function Group Definitions

WFG01 SS18 Water Treatment and Auxiliaries

WFG02 SS40 Condensate Polishing Plant (CPP) Common

WFG03 SS18 Ammonia Plant

WFG04 SS23 Sewage Plant

WFG05 SS42 Analysers in WTP

WFG06 SS42 Laboratory

WFG07 SS18 Resin Regeneration

WFG08 SS18 Ultrafiltration Plant

WFG09 SS18 Reverse Osmosis Plant

WFG10 SS18 Continious Electrode Ionisation Plant

WFG11 SS18 Gas Transfer Membrane

WFG12 SS18 Non Regenerable Mixed Bed

WFG13 SS18 Thickerner and Centrifuge

WFG14 SS18 Evaporator / Crystallisers

Table 3: Low Pressure Services Function Group Definitions

LFG01 SS25 Auxiliary Cooling

LFG02 SS20 Potable Water and Distribution

LFG03 SS19 Fire Water & Floor washing

LFG04 SS21 Demin Water Distribution

LFG05 SS17 Raw Water (off site)

LFG06 SS17 Raw Water (local)

LFG07 SS23 Clean & Dirty drains recovery

LFG08 SS12 Fly Ash Conditioning Water

LFG09 SS16 Bottom Ash Cooling (SSC)

LFG10 SS15 Course Ash Conveyor belt Washing

LFG11 SS12 Ash dump make-up water

LFG12 SS12 Ash dump irrigation & dust suppression

LFG13 SS24 Coal Stock Yard Pollution Control dam water recovery

LFG14 SS16 Mill Reject Water

LFG15 SS4 Compressors

LFG16 SS2 Diesel Fuel oil plant

LFG17 SS2 Turbine lubricating oil storage

LFG18 SS2 Main daily oil store

LFG19 SS2 Dirty oil collecting and storage

Table 4: Coal Function Group Definitions

CFG01 SS10 Overland

CFG02 SS10 Stockyard

CFG03 SS10 Stacker & Reclaimer

CFG04 SS10 Terrace Coal



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Table 5: Ash Function Group Definitions

AFG01 SS11 Ash Overland

AFG02 SS11 Ash Stacker

AFG03 SS11 Ash Dump Equipment

AFG04 SS14 Terrace Ash

AFG05 SS14 Terrace Stacker/Reclaimer

AFG06 SS13 Dust Handling & Conditioning

Table 6: Other Systems Function Group Definitions

OFG01 SS3 H2 & N2 Plant

OFG02 SS5 Building Management System

OFG03 SS6 Continuous Emission Monitoring System

OFG04 SS22 Reservoirs (Clean & Dirty Water Dams)

OFG05 Common Plant HMI

EFG01 SS7 Station Electrical Reticulation

3.2.3.3.2.3 MISCELLANEOUS SYSTEMS

Those control and instrumentation system areas that do not fall within the function group definitions given in the tables above are allocated Function Groups in Table 7 below. The function group assignment of the miscellaneous systems is for the management of the engineering process purposes only because all the activities will be done per function group including clarifications and design freeze.

Table 7: Miscellaneous Systems Function Group Definitions

GFG01 SS52 Unit Equipment Room

GFG02 SS53 Commissioning Room (Aux Bay)

GFG03 SS54 Simulator

GFG04 SS55 Station Common Computer Room

GFG05 SS56 Common Plant Equipment Room

GFG06 SS57 Station Battery Room

GFG07 SS58 Unit Battery Room

GFG08 Plant Information System

GFG09 Control System Architecture / Functional Distribution

GFG10 Cabling



PAGE 31 OF 135133

3.2.3.4 PROJECT EXECUTION METHODOLOGY

3.2.3.4.1 GENERAL

The Contractor shall be responsible for carrying out all activities and supplying everything necessary to provide the Works in accordance with the requirements of the Specification. This includes clarification and co-ordination with process plant engineers, Other Project Contractors and the Engineer.

The overall methodology required for the execution of the entire Works is shown in Figure 5 below.

Overall Project Structure

Power Island 6

Contract Award

Activity

= Sectional Completion Dates

Power Island 6 Sectional Completion

Power Island 5 Power Island 5 Sectional Completion





Balance of Plant

Project Completion

Power Island Simulator Development

Ready for Power Island 6 Ready for Power Island 3

Ready for Power Island 6 FAT

Ready for Power Island 6 Training

Updated to as-Build Power Island 6 Updated to as-Build Power Island 3

Figure 5: Overall Project Structure

It shall be the responsibility of the Contractor throughout the execution of the different contract activities to address the following and obtain approval from the Engineer:

• Make recommendations and proposals for process control concepts and plant performance improvements.

• Recommend any cost-effective proposals.

• General assessment of the suitability of the control devices supplied by the Employer to achieve the required performance standards.



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• Submit and update documentation as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS)

The nature of this project is such that, four distinct and different methodologies are required for the execution of the Works, as described below.

3.2.3.4.2 EXPERTISE / EXPERTS PROVIDED BY THE CONTRACTOR

The Contractor shall provide all expertise required for the Works for all phases of the project for the duration of the Works.

Only individuals from the Contractor’s Parent Company that have a proven track record (as indicated in the individuals’ CVs) on a project similar to the Medupi Power Station in the last 7 years, from inception and initial design, shall be deemed experts for all the project phases for Power Island 6. Subsequent to Power Island 6 completion, experts can be replaced with local individuals and or others with equivalent experience subject to approval by the Engineer.

The Contractor shall provide process expertise in the form of identified process experts/specialist for the duration of the Works. Process experts shall have proven experience as leading design and commissioning engineers for the process plant similar to that of Medupi Power Station and not just for the control of the following process plant:

• Super critical once through boilers

• Large steam turbines (>700MW)

• Generator plant

• Station Electrical Reticulation (SER) system

• Coal and ash conveyor belt systems

• Pneumatic ash conveying systems

• Automated stacker and reclaimer systems

• Water Treatment Plant (WTP) areas

• Hydrogen and Nitrogen production plant

As a minimum, the process experts shall be fully involved and on-site for the full durations of the Technical Clarifications, Engineering, Installation, Cold/Hot Commissioning, Optimisation and Site Acceptance Testing. The process experts shall also attend clarifications conducted with Other Project Contractors in Europe (predominantly France and Germany)

The Contractor shall solve any process control problems encountered during execution of the Works.

The Contractor shall further provide control and instrumentation design, installation and commissioning expertise for all the Project Methodology phases.

Detailed CVs of each process and control and instrumentation system expert shall be submitted to the Engineer for approval. Replacement of any individual with another with equivalent experience shall be subject to the Engineer’s for approval.



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3.2.3.4.3 POWER ISLAND 6 METHODOLOGY

The methodology required for the execution of the Works on the first Boiler/Turbine Generator Power Island (Power Island 6) and associate Balance of Plant is shown in Figure 6 below. The Contractor shall undertake all activities of engineering and design from systems engineering through technical clarification, design freeze, production engineering, factory acceptance tests (FAT) and site integration testing (SIT) to installation, commissioning and optimisation.

The basis for the supply of all engineering deliverables is in the form of documentation relevant to the different activities as stated in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

Figure 6: Power Island 6 Project Methodology

3.2.3.4.4 BALANCE OF PLANT METHODOLOGY

The methodology required for the execution of the Works for the Balance of Plant is shown in Figure 7 below. The Contractor shall undertake all the activities of engineering and design from systems engineering through technical clarification, design freeze, production engineering, factory acceptance tests (FAT) and site integration testing (SIT) to installation, commissioning and optimisation.

Project Methodology – Medupi Power Island 6

System Engineering

Production Engineering

Procurement, Erection and Installation

Cold Commissioning

Hot

Optimisation

Power Island 6 Design Freeze

Power Island 6 Factory Acceptance Test

Power Island 6 Site Integration Test

Power Island 6 Commissioning

Power Island 6 Sectional

Contract

Simulator

C&I Activity

= Sectional Completion Dates Capability Acceptance Test

Operator & Engineering

FMECA

Alarm Rationalisation

RAM



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The basis for the supply of all engineering deliverables is in form of documentation relevant to the different activities as stated in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

Project Methodology –per BOP area

Figure 7: Balance of Plant Methodology

3.2.3.4.5 SYSTEM ENGINEERING

3.2.3.4.5.1 GENERAL

Systems engineering is defined as being all activities necessary to ensure that the individual parts of the control and instrumentation system as well as the complete control and instrumentation system operates as an integrated and consistent system with itself and with the rest of the plant. All system engineering activities shall be conducted on a Function Group (FG) basis. The methodology required for the execution of the Works during the system engineering phase is illustrated in Figure 8 below.

System Engineering


Procurement, Erection and Installation

Cold Commissioning

Hot Commissioning

Optimisation

Design Freeze Completion

Factory Acceptance Test Completion

Site Integration Test Completion

Commissioning Complete

Sectional Completion

System Engineering Start Date

Operator & Engineer Training

Capability Acceptance Test Completion

Activity


FMECA

RAM



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System Engineering Methodology – per Function Group (FG)

FG InvestigationWork

Preparation of FG documentation

Review of FG

documentation

Update of FG documentation

Submission of FG documentation to Engineer

Submission of Updated FG Documentation to Engineer

Technical Clarification Meeting

Engineer Acceptance & Design Freeze

FG System Engineering Start Date

Employer Activity

= Sectional Completion DatesReview of updatedFG documentation

Contractor Activity

Process OEM Involvement

Other’s Activity

Figure 8: System Engineering Methodology

The system engineering activity includes the Contractor’s interfacing and participation with the Engineer, other process plant Original Equipment Manufacturers and Other Project Contractors through clarification meetings in order to reach the joint mechanical and control and instrumentation design freeze. The main clarification meetings shall be held in South Africa, but secondary clarification meetings might be required at the Other Project Contractors (process plant Original Equipment Manufacturer’s) facilities mainly based in Europe.

The Contractors information investigation work per Function Group shall include:

• Review, clarification and verification to ensure that the process plant Original Equipment Manufacturers’ P&ID, process flow diagrams, logic diagrams and operating philosophies are consistent with the Contractor’s Performance Requirements.

• Review, clarification and final compilation of the Schedules provided by the process plant Original Equipment Manufacturers including the Instrumentation and Drive & Actuator schedules, Valve Lists, Alarm Lists and Functional IO Blocks. Any discrepancies identified are red-lined by the Contractor and submitted to the Engineer for approval.

• Verification of the sizing and suitability of all valves and actuators provided by Other Project Contractors and provided as part of the Works. The Contractor shall submit a report of his actuator investigation work findings to the Engineer as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) . The Contractor shall be responsible for checking the valve characteristics including but not limited to the following:



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• Verify the valve design, body and trim materials; and pipe line connections conform with the specified project design details. Consider any alternative valve design offered by the vendor for claimed optimum application suitability reasons.

• Verify the valve body and connection pressure – temperature rating values cover the specified process design maximum conditions.

• Verify compliance with the specified process conditions; ensuring that any valve sizing parameters ie fluid specification, minimum, normal and maximum flow rates, inlet / outlet pressures at minimum, normal and maximum flows, temperature at flow conditions, and density values are correctly followed together with any specified inherent valve characteristic (equal percentage for the preliminary design stage). Consider predicted noise values against project specified parameters.

• Verify linear valve actuator thrust calculations against specified pressure drop process conditions at closed valve. Rotary valves also require torque calculations for flowing conditions. Check the selected actuator output at the specified supply parameters exceed the calculated values with a minimum 20% margin. Check the actuator action on supply failure is correct.

• Verify the 0 – 100% stroking speed value is commensurate with any specified process loop response / performance requirements.

• Verify the actuator positioning control mechanism conforms with the specified control signal range.

• Verification of all schedules and P&IDs against the requirements of the Operating Philosophies, this Specification and the RAM figures specified in Section 3.2.3.5.1 of this Specification for the control and instrumentation systems. Any discrepancies identified are red-lined by the Contractor and submitted to the Engineer for approval.

System engineering shall include the development of all function and schematic diagrams, control strategies and descriptions, as well as operator interface requirements to enable the technical clarification to be conducted in conjunction with the Engineer.

The Contractor shall be responsible for the development and engineering of control philosophies of the relevant plant areas and for submitting and maintaining documents as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

The system engineering documentation shall conform to all the requirements of the documentation synopsis as defined in Section 3.2.3.8.2 and shall be in an adequate state of completeness to technically clarify the respective plant system and control and instrumentation system.

The Contractor shall be responsible for the development of an Alarm Management System (AMS) that will meet the performance requirements specified in Appendix 15 – Minimum Assessment and Testing RequirementsAppendix 15 – Minimum Assessment and Testing Requirements. The Contractor shall apply a common alarm generating and display philosophy throughout the entire power station in accordance with GGPP1511 and EED-GTD-C&I-006 in Appendix 14Appendix 14.

During system engineering, the Contractor shall provide a dedicated Alarms Champion who shall manage the Alarm rationalisation process in order to meet the performance requirements of GGPP1511 and EED_GTD_C&I_006 in Appendix 14. This shall include but is not limited to the following:



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• Coordinate the Contractor’s alarm engineering effort

• initiate and maintain a cooperative dynamic with Other Project Contractors and the Engineer

• submit templates and collect all the alarm points, associated procedures and documentation, from Other Project Contractors and the Engineer, and create and update a preliminary Master alarm database, which will be the starting point of the rationalisation process.

• organise and attend the design and review meetings

• document all outputs and actions of the review meetings

• provide an Alarm Philosophy document which shall be submitted for the Approval of the Engineer and which shall be distributed to all parties involved in the Alarm Rationalisation process.

• test the Alarm Rationalisation performance on the actual system utilising the Contractor’s Alarm Management and Diagnostic System.

System engineering activities shall be executed by the Contractor in active co-operation with the Engineer. The Engineer will be responsible for maintaining the minutes of the meetings and records of changes to scope.

The Contractor shall take responsibility for collecting all data for all the design work. This includes process/plant data and information from the Engineer and Other Project Contractors to enable the design to be completed.

Detailed engineering of the interfaces within the Works and the interfaces to other systems shall form part of the Works.

The Contractor shall perform the function of co-ordinator and technical leader and takes full responsibility for all technical interfaces between the control and instrumentation system and other systems (e.g. switchgear, generator control and protection, synchroniser, turbine control and protection, etc).

Appendix B contains typical documents concerning System Engineering. Detailed documentation and procedures shall be submitted to the Engineer for approval.

3.2.3.4.6 TECHNICAL CLARIFICATION

Technical clarification is where the Contractor shall undertake the engineering and design activities that clarify with the Engineer and Other Project Contractors all the technical issues that are necessary to permit the Contractor to start production engineering.

All equipment having long lead time delivery shall be planned and technically clarified early in the technical clarification stage to allow early production engineering to commence. The technical clarification and design freeze activities shall be phased to suit the Key Date requirements.

The Contractor shall review, clarify and verify Other Project Contractor’s documentation, which may be in different formats, supplied according to Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) The Contractor prepared FG documentation, as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) , for the technical clarifications shall be provided to the Engineer 28 days prior to the start of the respective technical clarification.



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In the technical clarification, the Engineer will review the updated performance, functional, and equipment specifying documentation and the Contractor shall prepare formal documentation for design freeze.

Within 3 days of the technical clarification meetings being concluded, the Contractor shall provide three copies of the updated FG documentation as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) . The Engineer’s approval of clarification meeting documentation will be in 7 days of receipt.

As the design and documentation is agreed between the Contractor and the Engineer, it shall be formally signed off as approved by the Engineer.

The Contractor shall perform RAM and FMECA studies on the detail design of the control and instrumentation as per Section 3.2.3.5.1.5.

Design freeze is where the Engineer accepts the final performance, functional and equipment specifying documents as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) , and the Contractor shall be authorised to proceed with detailed engineering and design (production engineering).

3.2.3.4.7 PRODUCTION ENGINEERING

3.2.3.4.7.1 GENERAL

Production engineering is defined as all the detailed engineering and design activities of the Contractor that translate the requirements finalised at design freeze into a fully functional control and instrumentation system.

The Contractor shall submit, on a continuous basis, all design calculations and documents for approval by the Engineer.

The Contractor shall utilise the AMS to rationalise all alarms to the operator according to the Eskom Guideline EED_GTD_C&I_006 and provide documentation from the alarm rationalisation process as per Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

A list of the minimum documents required by the end of the production engineering stage is defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

3.2.3.4.7.2 FACTORY ACCEPTANCE TESTING

Only the first Power Island (Power Island 6), Balance of Plant and WTP control and instrumentation system shall undergo Factory Acceptance Testing, the remaining Power Islands shall only undergo Site Integration Testing.

The factory acceptance testing shall test the following:

• Hardware functionality and performance

• Application software functionality

• System performance

All equipment shall be factory tested prior to shipment. The Engineer may appoint representatives from the Engineer and Other Project Contractors to inspect all parts during manufacture and to be present at any of the tests specified.



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The Engineer will specify hold and witness points during the fabrication and factory testing of the control and instrumentation systems. The Contractor shall issue preliminary notification of such hold and witness points with a 28 day advance notice to the Engineer, and confirms such hold and witness points at least seven days prior to the activity.

For inspection abroad and in South Africa, arrangements for witnessing shall be made through the Engineer. Once an inspecting authority is established, all third party equipment shall also be incorporated in the inspections. A minimum of 8 weeks notice shall be given by the Contractor for such inspections.

3.2.3.4.7.2.1 PRE-FAT

The Contractor shall conduct a pre-factory acceptance test at the Contractor’s factory in preparation for the FAT with the Engineer.

During the pre-FAT the Contractor’s engineers shall test and verify the individual software and hardware modules of the design specification as agreed upon at design freeze, as well as the integration of all hardware and software of the Works.

The Contractor’s pre-FAT tests shall be documented as part of the Contractor’s QC procedure. The Contractor shall submit the QC procedures and pre-FAT test and inspection results to the Engineer prior to the commencement of FAT as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

3.2.3.4.7.2.2 FAT

During FAT, the Contractor shall demonstrate that the control and instrumentation system meets the requirements of this Specification. The Contractor, Other Project Contractors and the Engineer shall witness the FAT.

The Contractor shall guarantee that all system hardware and software is available and operational in time for the individual tests. Simulated inputs shall be used for the tests. During the tests, the system shall be exercised to determine the integrity of the system and the system’s compliance to the Specifications.

The Contractor shall perform coordinational management in order to ensure that the third party systems, including the respective Engineers, are available for the DCS FAT. The logistics implementation of the same shall be the responsibility of the Employer.

The following equipment shall be tested, as a fully connected and integrated system, during the Power Island 6 control and instrumentation system & Balance of Plant control and instrumentation system FAT:

• All control system equipment

• All protection system equipment

• All control and protection system software as agreed by the Engineer

• Selected HMI equipment

• Selected cabling & associated Infrastructure equipment

• Selected expert systems (digital interfaces)



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• All 3rd party interfaces

• Selected power supplies equipment

The minimum FAT testing and inspection requirements are defined in the standard, IEC 62381 1st addition (2006-11) and in Appendix 15 – Minimum Assessment and Testing Requirements. The Engineer will determine if any further testing is required in addition to that specified, such as that of any new technologies being used.

The Contractor shall prepare a detailed test procedure in preparation for FAT. The proposed test procedure shall be prepared by the Contractor and submitted to the Engineer for approval during the system engineering stage. The final test procedure shall be prepared by the Contractor and submitted to the Engineer for approval at least 28 days prior to the scheduled test date.

As a minimum, the proposed FAT procedure identifies the following:

• Major test activities

• Comprehensive list and description of the individual tests to be performed

• How the tests are to be prepared and conducted

• Test dates and durations

• Checklists - how the test results will be documented

• Acceptance criteria

• How the identified discrepancies will be processed

• Re-testing requirements

A Final FAT report shall be prepared by the Contractor that includes the following as a minimum:

• Test procedures used during FAT

• Detailed test results

• Discrepancies identified during the tests

• Resolution of the discrepancies

• Re-tests conducted and results thereof

• FAT certificate

The Contractor shall submit the Final FAT Report to the Engineer for approval. FAT Completion shall be achieved upon approval of the Final FAT Report by the Engineer.

Appendix B contains typical documents concerning FAT. Detailed documentation and procedures shall be submitted to the Engineer for approval during System Engineering.



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3.2.3.4.8 PROCUREMENT, ERECTION & INSTALLATION

3.2.3.4.8.1 GENERAL

This stage shall consist of the procurement, installation, and on-site inspection and testing of all supplied items forming part of the Works as well as other items that the Engineer has specified.

One hard copy and one soft copy of the production engineering and design documentation, as listed in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) , shall be prepared and issued by the Contractor to the Engineer for approval. This is required 28 days before construction is due to commence.

Such tests as may be required by the Engineer shall be carried out by the Contractor after erection to prove compliance with the Specification irrespective of any tests, which may have been carried out at the manufacturer’s factory.

The Engineer may specify hold and witness points during the installation and testing stages of the project. The Contractor shall issue preliminary notification of such hold and witness points by giving not less than 28 days advance notice to the Engineer, and confirms such hold and witness points at least 7 days prior to the test activity.

The Contractor shall provide the entire required test Equipment for site testing.

System commissioning phase and milestones shall be as defined in standard IEC 62337 (2006-11).

3.2.3.4.8.2 SITE INTEGRATION TEST (SIT)

Site Integration Testing (SIT) shall take place at the Medupi site after the equipment is delivered to site and has been installed, powered up and interfaced to the existing plant.

SIT shall be carried out to ensure the correct performance of the control equipment, to ensure safety of plant and personnel, and to ensure compliance of the control and instrumentation system with the Specification before commissioning of the plant commences.

As a minimum, the SIT testing and inspection activities shall be provided by the Contractor for the Works consists of the site integration and site acceptance activities defined in the standard, IEC 62381 1st edition (2006-11) and the testing activities defined in Appendix 15 – Minimum Assessment and Testing Requirements.

The Contractor shall prepare a detailed test procedure in preparation for SIT. The proposed test procedure, together with test dates, shall be prepared by the Contractor and submitted to the Engineer for approval during the system engineering stage. The final test procedure shall be prepared by the Contractor and submitted to the Engineer for approval at least 28 days prior to the scheduled test date. A Final SIT Report shall be prepared by the Contractor inclusive of the following as a minimum:

• Test procedures used during SIT

• Detailed test results

• Discrepancies identified during the tests

• Resolution of the discrepancies

• Retests conducted and results thereof



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• SIT certificate

In the event of an error in any test (hardware or software) the fault shall be logged and analysed. If the Engineer determines the fault is of a minor nature, the Contractor shall be allowed to rectify the fault and the item shall be re-tested for the full duration.

Major faults, for example, process server failure, system stall, bus failure terminate the SIT. This includes all operator and engineering interventions required to assist the control system during the testing. The Contractor shall rectify the fault and re-starts the SIT after proving the compliance and performance of the rectified piece of equipment by carrying out the appropriate diagnostic tests.

When all tests have been successfully carried out and the Final SIT Report is approved by the Engineer, the system shall be classified as ‘ready for use’. The control and instrumentation system is then deemed ready for cold commissioning (functional testing).

3.2.3.4.9 COLD & HOT COMMISSIONING

3.2.3.4.9.1 COMMISSIONING

Commissioning is defined as bringing into service all items of the Works, and meeting the functional requirements and performance criteria of the Specification. This includes all necessary testing and verification of the stated performance criteria.

The Contractor shall commission all interfaces to control equipment provided by the Engineer. The Contractor shall co-operate fully with the Engineer and the Other Project Contractors in the commissioning of the plant for which the Employer will supply the portion of equipment, systems and control and instrumentation systems.

The Contractor shall provide all the test equipment required for the commissioning of the individual modules, the sub-assemblies and the functional groups.

Commissioning shall not start until the commissioning documents as defined in Appendix 14 – Project Standards has been approved by the Engineer.

The equipment covered by the Specification shall be installed and completed in all respects by the dates stated in the Accepted Programme. The Contractor shall provide sufficient personnel for the satisfactory and timely commissioning of the equipment.

Before the equipment is placed in service, the Contractor shall ensure that it is in a suitable and safe condition for use. This shall include all tests required to ensure safe and accurate measurements such as blow through of measurement lines, pressure testing of measurement lines, filling of reference pots, leak testing etc.

Prior to the commencement of cold commissioning, the Engineer will nominate a representative to co-ordinate the commissioning of all equipment forming an integral part of the plant being commissioned.

The Employer will use the Works, without taking over the Works, before completion of the commissioning, optimisation and capability testing of the Works and associated plants.



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3.2.3.4.9.2 COLD COMMISSIONING

This stage consists of all field equipment checks, loop checks, drive interface checks, and testing system functionality up to but excluding providing actuation power and process medium in the plant, energy whether electrical, hydraulic or pneumatic.

3.2.3.4.9.2.1 FUNCTIONAL TESTS

The functional tests form part of the cold commissioning of the control and instrumentation system and include the checking of all measurement loops, interlocks, sequence controls, analogue controls and interfaces to systems provided by Other Project Contractors.

The execution and documentation of loop checks shall be used upon standard IEC 62382 (2006-11).

3.2.3.4.9.2.2 VALVE AND DAMPER ACTUATOR TESTS

All dampers, analogue and binary valves shall be locally and remote manually operated and checked for correct operation by the Contractor. These tests shall be conducted in conjunction with the Engineer and Other Project Contractors. Special care shall be given to safety aspects, rotation direction, special function limits, torque settings, position indication and mechanical stops.

The Contractor shall be responsible for the setting of limits (stroke checking), torque settings and position indication.

Data sheets shall be provided for all valve and damper actuators, stipulating as a minimum requirement torque setting, special application requirements where eg auxiliary limits are used or where the actual stroke setting differ from the possible stroke and precautionary notes or procedures that need to be observed during setting of the actuator.

3.2.3.4.9.2.3 ELECTRICAL DRIVE TESTS

All electrical drives are local and/or remotely operated and checked for correct operation by the Contractor. These tests are conducted in conjunction with the Engineer and Other Project Contractors. Special care shall be given to safety aspects, motor rotation direction and protection.

3.2.3.4.9.2.4 INSTRUMENT CHECKS

Calibrations of all instrumentation forms part of the Works and calibration data sheets shall be provided and signed by both parties and included as part of the documentation package for the Works. Calibration sheets for equipment incorporated in the asset management system shall be automatically generated and digitally signed by both parties. The format, content and other requirements for generating these calibration certificates will be clarified during the system engineering phase.

The Contractor shall submit the Cold Commissioning test results to the Engineer at the conclusion of cold commissioning and request the commencement of hot commissioning.

3.2.3.4.9.3 HOT COMMISSIONING

3.2.3.4.9.3.1 GENERAL



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Hot commissioning is where the plant processes are placed into operation in conjunction with the control and instrumentation system and Other Project Contractors.

The Contractor shall be responsible for the commissioning of the complete control and instrumentation system including the final control elements i.e. drives, switchgear interposing relays, actuators, solenoid operated valves (SOV), existing actuators and their interposing relays, bus interfaces and their protocols, as well as the HMI, station information system and LAN connection. The commissioning activities shall be carried out in conjunction with the Engineer.

The Contractor shall be responsible for the hot commissioning of all the equipment forming part of the Works and the interfaces to systems provided by Other Project Contractors to satisfy the requirements of the Specification. The Engineer is responsible for the preparation of the plant, mechanical and electrical standby and process ready state, for hot commissioning. However, for that portion of the equipment, which cannot be commissioned separately from other plant, the commissioning is at the discretion of the Engineer for the particular stage of commissioning concerned.

In cases where various components are connected to form an integrated system, the Contractor, at the time of commissioning, shall carry the responsibility for the correct functioning of the whole of the system.

If a defect is identified in the equipment interfacing or external to the Contractor’s scope the Contractor shall request the Engineer to rectify the defects.

3.2.3.4.9.3.2 OPERATIONAL ACCEPTANCE TEST (OAT)

Commissioning shall be concluded with the Operational Acceptance Test (OAT). The Contractor shall request commencement of operational acceptance test from the Engineer.

The OAT shall include the checking of all interlocks and protections, sequence controls and analogue controls. The minimum OAT testing and inspection requirements are defined in Appendix 15 – Minimum Assessment and Testing Requirements.

The Contractor shall produce a detailed OAT test procedure 28 days in advance for approval by the Engineer. The OAT procedure includes as a minimum, the loop tuning procedures and acceptance criteria for the individual loops.

The control and instrumentation system shall be pre-tuned in order to prevent deviation limits of process parameters from exceeding the maximum permissible values defined during the system engineering stage.

A Final OAT Report shall prepared by the Contractor. The Contractor submits the Final OAT Report to the Engineer for approval. Commissioning completion is achieved upon approval of the OAT Report by the Engineer.

3.2.3.4.10 OPTIMISATION STAGE

3.2.3.4.10.1 GENERAL

The optimisation stage consists of plant optimisation and control and instrumentation system optimisation, and the Capability Acceptance Test (CAT). The testing requires the Employer’s System Operator permission and is subject to the national electricity grid availability requirements. This shall require that the Contractor make available the



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optimisation resources during any time of the day when the national electricity grid is available. The probability is high that this might require more than eight consecutive hours and or non standard working times.

The time allocated for plant optimisation shall allow for plant tests and modifications to take place. As the mechanical plant is optimised, the Contractor shall provide commissioning resources for this stage, as well as design resources, to undertake control and instrumentation modifications to support the plant modification requirements.

3.2.3.4.10.2 CONTROL AND INSTRUMENTATION SYSTEM OPTIMISATION

Once the Operational Acceptance Test is successfully completed, and the plant optimisation is sufficiently complete, the control and instrumentation system optimisation testing stage commences.

During this stage, the Contractor shall fully optimise the control and instrumentation system and ensures that the quality requirements for the control of the plant are achieved.

3.2.3.4.10.3 CAPABILITY ACCEPTANCE TEST (CAT)

Optimisation is concluded with the Capability Acceptance Test (CAT). The Contractor shall request commencement of CAT from the Engineer.

The Capability Acceptance Test shall prove that the control and instrumentation system is fully optimised to meet the Specification requirements. The tests shall also ensure the safety of the plant.

The Contractor shall produce a detailed Capability Acceptance Test procedure 180 days in advance for acceptance by the Engineer. The testing procedures will be distributed and have to be accepted by the Other Project contractors.

The minimum CAT testing and inspection requirements are defined in Appendix 15 – Minimum Assessment and Testing Requirements.

A Final CAT Report shall be prepared by the Contractor. The Contractor shall submit the Final CAT Report to the Engineer for approval. Capability Acceptance Test completion shall be achieved upon approval of the CAT Report by the Engineer.

3.2.3.4.11 “AS BUILT” DOCUMENTATION PACKAGE

Two sets of 'As Built' documentation, as listed in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) shall be supplied by the Contractor to the Engineer. Approval of the ‘As Built’ documentation is a pre-requisite for the Sectional Completion of the Plant Area concerned.

The documents shall be reviewed by the Engineer for correctness and conformance to the accepted design.

3.2.3.4.12 SIMULATOR METHODOLOGY

3.2.3.4.12.1 GENERAL

The methodology required for the execution of the Works for the Simulator is shown in Figure 9 below. The Contractor shall undertake all the activities of engineering and design



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from system engineering through technical clarification, design freeze, production engineering and acceptance tests to installation and commissioning as stipulated in the sectional Completion Dates of the Works.

The basis for the supply of all engineering deliverables shall be in the form of documentation relevant to the different activities as stated in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

The simulator will be used for operator training to be completed before the start of hot commissioning and for checking the control and instrumentation system logics before the start of the control and instrumentation system FAT.

Since the requirement for the operator training is early in the build process, space is provided in the auxiliary bay 16m level at Power Island 6 for a temporary simulator suite that should house the simulator. Space is provided in the auxiliary bay 16m level at Power Island 4 for the permanent simulator.

The Contractor shall furnish the temporary simulator suite to the same quality of finish and installation as for the permanent simulator suite. All cabling, lighting, furniture and plant and equipment shall be installed to the same standard as for permanent usage. Reliability and availability of equipment shall not be compromised by the temporary installation. All functionality shall be available in the temporary simulator suite.

3.2.3.4.12.2 SIMULATOR

The reference plant for the Simulator is Medupi, Power Island 6. The Simulator Methodology is given in Figure 9.



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Figure 9: Simulator Project Methodology

3.2.3.4.12.2.1 SIMULATOR PHASED APPROACH

The Simulator shall be delivered and used in four different phases in order to suit the different requirements for the use of the simulator viz. training of operators.

3.2.3.4.12.2.1.1 Simulator– Phase 1

The Simulator shall be based on the Power Island 6 DCS FAT data and the actual control and instrumentation system configuration and software. The simulator shall have the following functionality at the end of this phase ready for the initial training of the operator:

• DCS FAT software (logic and analog control)

• DCS FAT HMI Graphics

• Plant Process Models

• Simulation of hardware provided by Other Project Contractors.

• Emulation of the Works

Simulator Design Freeze

Project Methodology – Power Island Simulator

System

Engineering


Installation & Erection

PI Simulator Ready-for-Training (RFT)

Contract

Simulator

= Key Milestone Dates


Instructor & Engineer Training

PI Operator Training

PI 6 Sectional Completion

PI 6 Optimisati

on

PI Simulator Site Integration Test

‘As Built’

PI Simulator Sectional

Non-Simulator

PI Simulator Factory Acceptance Test

FAT PI 6 control and instrumentation system

PI Control System Hot

Update to PI 6

Move to permanent

room

PI 1 Sectional

= Simulator Usage Key Dates



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3.2.3.4.12.2.1.2 Simulator – Phase 2

The Simulator shall be based on the Power Island 6 fully commissioned and capability tested data. The simulator shall be a high fidelity replica of PI 6.

3.2.3.4.12.2.1.3 Simulator – Phase 3

The Simulator shall be based on the Power Island 6, 5 and 4 fully commissioned and capability tested data. The simulator shall be a high fidelity replica of PI 6, 5 and 4 inclusive of any retrofits.

3.2.3.4.12.2.1.4 Simulator – Phase 4

The Simulator shall be based on the Power Island 6, 5, 4, 3, 2 and 1 fully commissioned and capability tested data. The simulator shall be a high fidelity replica of PI 6, 5, 4, 3, 2 and 1 inclusive of any retrofits.

3.2.3.4.12.2.2 SIMULATOR SYSTEM ENGINEERING

During the Simulator system engineering phase the Contractor shall perform the standard activities of system engineering as outlined in earlier sections of this Specification.

In addition, the Contractor shall also be responsible for the collection and validation of all the simulator design data and interfaces with the Engineer and the Other Project Contractors and process plant Original Equipment Manufacturers. The Contractor shall make available, on a full-time basis, a simulation Engineer to collect and validate the simulator design data during the Simulator system engineering phase. In the event that the Contractor determines that a void or conflict in the design data exists, the Contractor shall identify such void or conflict and proposes alternate data, methods of filling the void, or resolution of the conflict and submits the proposed solution to the Engineer for approval. The Contractor shall be responsible for validating and updating of all design data in the simulator data register.

Simulator Design freeze is where the Engineer approves the final performance, functional, scope and equipment specifying documents for the Simulator and the Contractor shall be authorised to proceed with detailed engineering and design (production engineering). The Contractor shall submit documentation as listed in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) at Design Freeze for approval by the Engineer.

The Simulator Design Freeze completion shall occur after the actual control and instrumentation Power Island 6 control and instrumentation system Design Freeze completion to ensure that the Simulator remains in synchronisation with changes made to the reference plant during system engineering.



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3.2.3.4.12.2.3 SIMULATOR PRODUCTION ENGINEERING

During the Simulator production engineering phase the Contractor shall perform the standard activities of production engineering as outlined in earlier sections of this Specification.

In addition, to reduce the possibility of the Simulator not being consistent with the Engineer’s expectations at the time of factory acceptance testing, the Engineer shall be involved in reviewing and validating the progress being made by the Contractor throughout the production engineering phase. To this end, the Contractor shall schedule a minimum of five design review meetings at the Engineer’s offices during the production engineering phase. During the design review meetings the Contractor and Engineer shall review progress to date and conduct detailed reviews and validation of the developed simulator models.

The Contractor shall prepare a design report in preparation for each design review meeting. The design reports shall be submitted to the Engineer not less than 21 days prior to the relevant design review meeting.

During the Simulator FAT and pre-FAT the Contractor shall perform the standard activities of FAT and pre-FAT as outlined in Section 3.2.3.4.7.2 of this Specification.

The minimum tests and inspections conducted during the Simulator FAT are listed in Appendix 15 – Minimum Assessment and Testing Requirements.

3.2.3.4.12.2.4 SIMULATOR SITE INTEGRATION TEST

During the Simulator SIT the Contractor shall perform the standard activities of SIT as outlined in Section 3.2.3.4.8.2 of this Specification.

The minimum testing and inspection requirements for the Simulator SIT are listed in Appendix 15 – Minimum Assessment and Testing Requirements. The Simulator shall be approved as Ready for Training (RFT) by the Engineer upon successful completion of the Simulator SIT. The Contractor shall provide the Simulator RFT as required in the Key date schedule.

3.2.3.4.12.2.5 SIMULATOR UPDATE TO POWER ISLAND 6 ‘AS BUILT’ STATUS

The minimum inspection and test requirements for the Simulator ‘As Built’ Acceptance Test are specified in Appendix 15 – Minimum Assessment and Testing Requirements and is part of Phase 2.

The Contractor shall prepare a detailed test procedure in preparation for the ‘As Built’ Acceptance Test. The proposed test procedure, together with test dates, shall be prepared by the Contractor and submitted to the Engineer for approval during the system engineering stage. The final test procedure shall be prepared by the Contractor and submitted to the Engineer for approval not less than 28 days prior to the scheduled test date.

3.2.3.4.12.2.6 SIMULATOR UPDATE TO STATION ‘AS BUILT’ STATUS



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The minimum inspection and test requirements for the Simulator ‘As Built’ Acceptance Test are specified in Appendix 15 – Minimum Assessment and Testing Requirements and is part of Phase 4.

The Contractor shall prepare a detailed test procedure in preparation for the ‘As Built’ Acceptance Test. The proposed test procedure, together with test dates, shall be prepared by the Contractor and submitted to the Engineer for approval during the system engineering stage. The final test procedure shall be prepared by the Contractor and submitted to the Engineer for approval not less than 28 days prior to the scheduled test date.

The Simulator shall be accepted as Complete by the Engineer upon successful completion of the Simulator ‘As Built’ Acceptance Test.

3.2.3.5 CONTROL AND INSTRUMENTATION SYSTEM REQUIREMENTS

Appendix C contains typical datasheets of the field control equipment. Detailed datasheets for all system components shall be submitted to the Engineer for approval

during System Engineering.

3.2.3.5.1 CONTROL AND INSTRUMENTATION SYSTEM PERFORMANCE

3.2.3.5.1.1 LIFE EXPECTANCY

All control and instrumentation, protection system and control components shall be supported and maintainable for a minimum of 25 years. The Contractor shall provide his latest power plant proven technology for the Works. No unproven technology shall be allowed. The proven technology shall be available as fully functional systems as a minimum at 6 reference units each having more than 12 months operational experience. The control and instrumentation system shall be based on series 6 DCS.

3.2.3.5.1.2 RELIABILITY

The control and instrumentation system structure shall follow the mechanical plant and electrical power distribution configuration to minimise the effects of equipment failure on the overall plant. The control and instrumentation system shall be designed and configured through functional distribution of equipment for the following reliability:

• SAFETY

No single failure of any part of the Works shall lead to a condition that will endanger the safety of the plant or people or jeopardise the integrity of major plant.

• POWER ISLAND TRIP/LOAD LOSS

No single failure of any part of the Works shall cause a Power Island trip, forced outage or more than a 40% load loss.

• MULTI- POWER ISLAND TRIP

No single failure of any part of the Works shall cause a multi- Power Island trip.

• OPERATOR INTERFACE

No individual fault shall cause the loss of an operator workstation. No individual loss shall cause the loss of control or operator information.



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• TRANSMITTERS

All transmitters shall have a minimum long term stability of 0.15% drift in 6 years guaranteed for at least 6 years from the date of Taking-over. Prior to Design Freeze the Contractor shall provide a methodology for testing the long term stability requirement. The methodology shall be submitted to the Engineer for approval.

If, during the 6 year guarantee period the methodology for testing shows that the drift limit has been exceeded, the Contractor shall replace the device within 24 hours.

3.2.3.5.1.3 AVAILABILITY

The control and instrumentation system structure shall follow the mechanical plant and electrical power distribution configuration to minimise the effects of equipment failure on the overall plant. The control and instrumentation system shall be designed and configured through functional distribution of equipment for the following availability and the Contractor shall provide the availability calculations:

• CONTROL AND INSTRUMENTATION SYSTEM AVAILABILITY

The availability of the complete control and instrumentation system consisting of the individual sub-systems over its life in percentage of time shall be 99,99% or greater. The availability shall include for all software updates and upgrades, and planned and unplanned maintenance, but exclude hardware upgrades. This would require an emphasis on on-line maintenance of all control and instrumentation system components.

• PROTECTION SYSTEM AVAILABILITY

The availability of the complete protection systems over its life in percentage of time shall 99,999% or greater. The availability shall include for all software updates and upgrades, and planned and unplanned maintenance, but exclude hardware upgrades. This would require an emphasis on on-line maintenance of all protection system components, without putting the plant at risk.

• AVAILABILITY OF FIELD DEVICES

Field device availability shall as a minimum match that of the control and instrumentation system so that it does not constitute a weak link. This will require an emphasis on matching the MTTF and MTTR of the field equipment with that of the overall control and instrumentation system, on-line maintenance of field equipment, functional distribution of equipment, and matching of redundancy philosophies with mechanical and electrical systems.

All transmitters, excluding Humidity transmitters, position transmitters, vibration and seismic sensors, shall be certified to be used in a SIL 2 application.

All field instrumentation shall have a minimum MTTF of 100 years, if not SIL 2 certified.

The MTTF for all field installed plant and equipment forming part of the Works shall be tested by the Contractor from Sectional Taking-Over of Power Island 6 for at least a period of one year to prove compliance to the MTTF specification and SIL 2 rating. A separate test shall be done for each separate type, make and model of instrument



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and transmitter. Where the total number of failures for a particular test equals or exceeds 10, the MTTF shall be calculated as:

MTTF = (number of devices tested multiplied by the test period in hours) divide by the total number of failures.

Where the total number of failures of an individual test is <10, the MTTF shall be calculated assuming a single sided lower confidence of 70%.

The Contractor shall submit the reports on the tested MTTF and SIL compliance as per Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

3.2.3.5.1.4 PERFORMANCE OF THE INDIVIDUAL CONTROL LOOPS

For the individual control loops, the deviation between the Process Variable (PV) and the Set-point shall return to within 1% of the setpoint within 2.5 oscillations, depending on mechanical performance.

3.2.3.5.1.5 RELIABILITY, AVAILABILITY AND MAINTAINABILITY (RAM) STUDIES

The Contractor shall perform RAM (Reliability, Availability and Maintainability) studies on all major areas of plant in the Works according to PGZ 45-27 and PGZ 45-24 in Appendix 14 – Project StandardsAppendix 14 – Project Standards. The purpose of these studies is to achieve the following:

• Predicting the availability of various areas of plant.

• Performing LCC (Life-cycle costing) studies on plant by establishing their capital, maintenance, operating and unavailability costs.

• Performing trade off studies to arrive at the best combination of the capital, maintenance, operating and unavailability costs elements per plant type.

• Performing redundancy studies.

• Using the above studies to feed information into the maintenance optimisation programme.

All RAM calculation on control and instrumentation plant and equipment shall be done for the environmental condition that the equipment will be installed and operated in. Laboratory condition for RAM calculation shall not be acceptable.

Essential to the above process is the construction of an ABD (Availability Block Diagram) of the system and shall form part of the RAM study. The ABD shall show the interconnections between equipment for each of the subsystems making up the plant. All redundancies shall also be shown.

The latest VisualSPAR version at the time of the study, reliability simulation software package shall be used in performing the RAM analysis.

The Contractor shall supply the following information:

• RAM Reports as per the objectives listed above.

• The availability calculations for each subsystem and the complete system modelled in VisualSPAR.



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• The complete ABD models and software logic – the actual ABD VisualSPAR (latest version at the time of the study) software models. The ABD models and software logic provided by the Contractor, as part of the Works, shall be supplied in its entirety and shall be sufficient in itself for the Employer to replicate or re-create all the ABD calculations using only the VisualSPAR (latest version at the time of the study) software.

• Capital, maintenance, operating and unavailability cost estimates for those systems in their supply, for inclusion in the ABD.

• MTTF (Mean Time to Failure) for each type of equipment and the type of failure distribution i.e. Exponential or Weibull.

• MTTR (Mean Time to Repair) or MDT (Mean Down Time) and Availability estimates for those systems in their supply, for inclusion in the ABD.

• The estimates for MTTR, MDT and Availability are to exclude planned outages. The ABD prediction therefore will be a prediction of forced outage percentage.

• Subsystem level ABD’s indicating degree of redundancy if any and estimates as given above.

The Contractor shall carry out formal Failure Mode Effects and Criticality Analysis (FMECA) on all systems forming part of the Works. These studies shall be done in accordance with the requirements as laid down in the Eskom FMECA Guideline: PGZ 45-25 supplied in Appendix 14 – Project StandardsAppendix 14 – Project Standards.

The Contractor shall supply the information as per Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

3.2.3.5.1.6 CONTROL AND INSTRUMENTATION SYSTEM EXPANDABILITY

The Contractor’s design shall provide for later expansion of the control and instrumentation system such that future changes and enhancements can be readily incorporated. Up to 50 Automation Units shall be configurable per PI or BOP ring network. The spare capacity shall be demonstrated to the Engineer at design freeze.

The Contractor shall provide for the maximum between the following and that specified in Appendix 14 – Project Standards in his design, measured at Design Freeze, without the necessity for reconfiguring the design:

• 10% spare installed I/O of each type in a control and instrumentation system cubicle spatially distributed throughout the cubicle throughout the I/O modules.

• 20% reserve physical space in all cubicle racks (I/O, signal conditioning etc.), field panels, marshalling racks and cable racks.

• 10% spare installed terminals per cubicle

• 20% spare installed capacity in all multi-core cables (rounded up)

• 20% reserve power availability at full load use per area

The Contractor shall provide for the following at Completion without reconfiguring the design:

• The utilisation of all CPUs shall not exceed 45% loading during normal operation

• The Contractor must cater for full expandability range for bus loading

• 30% spare memory capacity for software expansions



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• 30% spare hardware and software capacity for the simulator

The Contractor shall provide a report on the control and instrumentation system expandability confirming each of the above parameters as tested by the Contractor before Taking-Over is certified.

The Contractor shall monitor the CPU and bus loading on a continuous basis from the Hot Commissioning to Taking-Over of the relevant Power Island. The report shall include the method utilised to monitor the CPU and bus communication loading as well as the loading for all operations. The normal and abnormal operation periods shall be clearly indicated in the report. The reports shall be provided as per the requirements of Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

Appendix J contains conceptual calculations for the System Expandability. Detailed calculations shall be submitted by the Contractor to the Engineer for approval during System Engineering.

3.2.3.5.2 CONTROL AND INSTRUMENTATION SYSTEM STANDARDISATION

The purpose of standardisation of control and instrumentation plant and equipment is:

• Reduced life cycle cost / cost of ownership cost

• Interchangeability of equipment

• Reduced the number of different types of equipment used on site, thereby also reducing spares holding requirements

• Reduced training requirements on different systems.

The Contractor shall develop a standardisation strategy for approval by the Engineer as per Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

The Contractor shall standardise on all similar plant and equipment provided for the complete control and instrumentation system for Medupi Power Station forming part of the Works. The Contractor shall notify the Engineer of issues related to non standardisation for control and instrumentation systems forming part of the Works and provided by Other Project Contractors.

The standardisation shall include for as a minimum the following aspects for all plant and equipment forming part of the Works, not limited to the items listed below:

• HMI (make, model and size)

o Screens

o Input devices

o Processor units

o Desks

• Computers and Servers (make, model and 19” rack mounting)

• Network equipment (make and model)

o Switches and hubs

o Fibre optic cable (type of cable and terminations)



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• Cubicles and enclosures (make, size, construction and colour)

• Control system processor units (make and model)

• Control system input/output units (model, series, specifications and form factor)

• Control and instrumentation system’s / PLC’s (make, model and series)

• Field instrumentation

o Instrumentation for each measurement type (make, model, series, accuracies, ranges, process connections, mountings and terminations)

o Actuators (make, model, series, mountings and terminations)

o Impulse piping (size, material, connections and arrangements)

o Transmitters (make, model, series, accuracies, mountings, housings and terminations)

o Transmitter racks (arrangement and mountings)

o Junction boxes (size, colour, arrangement and mounting)

o Splitter boxes (size, colour, arrangement and mounting)

o Instrument isolation valves and manifold (size, make, model, arrangement and connections)

o Condensate pots (make, size, arrangement and connections)

• Cabling (routing, make, size, type, number of conductors, terminations)

• Racking, truncking and conduits (routing, make, size, type and mountings)

Standardisation shall not compromise the plant and/or the control and instrumentation system performance.

3.2.3.5.3 PLANT CONTROL PHILOSOPHY

3.2.3.5.3.1 LEVEL OF AUTOMATION

The operating manpower that shall be used by the Contractor to determine the level of automation and that should be used as a guideline in the designing of the Operator interfaces are as follows:

• 1 x Operating Manager

• 1 x Shift Manager per Shift

• 6 x Power Island Controllers per Shift

• 6 x Senior Plant Operators per Shift

• 1 x Electrical Controller per Shift

• 1 x Senior Electrical Plant Operator per Shift

• 1 x Balance of Plant Controller per Shift

• 1X WTP Controller per Shift

• 2 or 3 x Senior Balance of Plant Operators per Shift

The philosophy is based on a 5 shift cycle, and the respective Senior Plant Operators will also be responsible for the issuing of plant permits.



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The level of automation and the design of the HMI shall be such that during normal base load operation, three units shall be operated by one operator without operator overload.

Within the mechanical limitations of the plant, and as far as reasonably possible the system shall be configured for one pushbutton start-up and shut down of the unit based on the operating sequences provided by the Other Project Contractors and Appendix 16 (Employer Minimum Requirements for Level of Automation).

3.2.3.5.3.2 ALARMING AND EVENT RECORDING

The Contractor shall apply a common alarm generating and display philosophy throughout the entire power station in accordance with GGPP1511 and EED-GTD-C&I-006 in Appendix 14Appendix 14.

The control and instrumentation system shall include an integral Sequence of Events (SOE) Recording function for all parameters and events. A standard philosophy shall be followed throughout the entire power station. Event recording shall be at the minimum of 1 millisecond.

3.2.3.5.3.3 CONTROL FUNCTIONAL SPECIFICATION

The required analogue control and binary control (sequence control, protection and interlocking) shall be specified by a written description and be read in conjunction with the Instrument Schedule, Drive & Actuator Schedule and the P&ID’s. The plant operating philosophies for the Power Island and Balance of Plant, together with the plant descriptions of each system, are detailed in Appendix 10 and Appendix 11. The Contractor shall use this information as the basis to engineer the control and instrumentation system.

As a minimum the following functions shall be catered for by the control and instrumentation system:

Load Cycle

The system shall provide as a minimum the following capability for all load segments:

• Within the full control range of the mechanical capability of the system, fully automatic operation (all control loops on automatic and in co-ordinated mode)

• The minimum commited control range shall be between 40% and 100% MCR.

• Load following capability. (Boiler and Turbine following)

• Compliance to the NER Grid Code

• AGC functionality as per the NER Grid Code and Section 3.2.3.5.10.19.

• Base load operation

• 2 shifting

Runbacks

When a Power Island is on load and a trip, malfunctioning process plant or abnormal condition has been detected, the control and instrumentation system shall take specific automatic runback actions, capability operation, in parallel with any possible trip functions,



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to place the plant and major components in a safe, stable and controllable operating state.

No fuel oil support should be required to maintain combustion stability at loads between 40% and 100% MCR during normal operating conditions. The control objective is to reach this lower energy state, minimum load, in a controlled manner, and to remain in a controlled stable state. This requirement is necessary to enable adequate time for the operator to decide on further actions (e.g. re-start or total shutdown of plant or plant components).

Power Island Islanding

The control and instrumentation system of a Power Island shall be capable of tripping to house load and continued stable operation under unit-islanded conditions. The Power Island shall be islanded in all cases of network disturbances which would otherwise lead to plant shutdown.

All the requirements of the Network Code of the NERSA Grid Code (GCR 2) and Generation Standard GGS 0500 shall be fulfilled.

3.2.3.5.3.4 GENERAL DESCRIPTION OF THE SEQUENCE / BINARY CONTROL

The primary objective of the binary control is to:

• Secure the safety of plant

• Increase the availability of the plant by correct and timely switch-over of auxiliary plant and devices

• Relieve the operator of routine and standardised tasks such as automatic adjustment of some plant auxiliaries depending on plant load

• Provide protection of the main and auxiliary plant by prudent use of protection functions and interlocks

3.2.3.5.3.4.1 BINARY CONTROL SUB SYSTEMS

The binary control consists of control sub-systems for sequence control, interlock logic and group controls for the plant areas.

The levels of control are:

• Individual drive control (IDC)

• Subgroup control (SGC)

• Group control (GC)

Binary systems shall include for the provision of fully automatic, semi-automatic and manual start up and shut down of the plant including the total plant on a unitised basis, group and sub-group control and individual drive control

The binary control shall be based on a hierarchical structure and the operator shall have direct access for manual control at any level of control in the hierarchy. Binary controls can be overridden, except for protection interlocks or permissive interlocks, which shall remain in operation at all times. After manual intervention, on returning to automatic mode of operation, the automatic sequence program must be able to continue from the correct point in the sequence program.



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3.2.3.5.3.5 GENERAL DESCRIPTION OF ANALOGUE CONTROL

All operations required for start-up, shutdown, load changes by the operator, load changes by the National Control Centre and primary governing shall be performed by means of the control and instrumentation system. The performance of the plant under all of these conditions shall be safe and efficient, with maximum reliability and availability.

3.2.3.5.3.5.1 PLANT CONTROL MODES WITH LOCAL CONTROL FACILITIES (LCS & LCP)

Where local control facilities are required, the following distinct modes of operation shall be provided:

• Automatic

• Remote manual

• Local manual

• Test mode

Selections of the mode of operation shall be available at group, sub group and device level. The technical guideline, EED_GTD_C&I_007 in Appendix 14 – Project Standards details the required mode selection philosophy for plant and equipment with local control facilities.

3.2.3.5.4 CONTROL AND INSTRUMENTATION SYSTEM FUNCTIONS

3.2.3.5.4.1 GENERAL

The Contractor shall provide a fully integrated, working system which meets safety, reliability and operability criteria and performs all modulating control, binary control, process interlocking, safety and protection functions and supervisory functions as detailed in the Specification.

The control and instrumentation system shall employ a consistent and integrated architecture throughout for all functions specified in this Specification.

Although the power station control and instrumentation system shall be integrated on an information level with all information available to all Power Islands and the Balance of Plant, the control and instrumentation system shall be structured such that all Power Islands may be operated and controlled completely autonomously from other Power Islands. No control hardware and equipment shall be shared between two Power Islands. Where plant areas are common to the Power Island, it shall be incorporated in the Balance of Plant control structure. No sharing of network equipment shall be allowed between Power Islands and between the Power Islands and the Balance of Plant areas such as the WTP, Coal, Ash, and LPS.

The structure of the system shall accommodate both functional and geographical distribution (up to 10 km) of the hardware and software over the plant, while allowing system wide access to distributed data.

The control and instrumentation system implemented shall be the Contractors standard configured system, not modified or adapted to specific requirements ensuring that any further upgrades to software and hardware remain standard and no special adaptation or configuration are required for the implemented design.



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The control and instrumentation system shall be a fully programmable, micro-processor-based process control and instrumentation system designed and suitable for application in the power plant industry.

The system shall perform all analogue and binary control, signal conditioning, signal acquisition, signal validation, data communications, engineering functions, configuration management, information processing, asset management and HMI, to provide a complete functioning control and instrumentation system.

The system shall provide various forms of protection and allows for the installation of system components in harsh or hazardous power plant environments.

The control and instrumentation system shall use industry standards to the maximum extent possible.

Any changes made to the control and instrumentation system database shall be made real-time and on-line with the exception of the boiler protection safety system where firmware updates might be made and tested off line. All changes shall be effective without restarting any part of the system. Batch data processing shall not be allowed.

The control and instrumentation system shall be configured so as to support online maintenance. Appendix G contains typical procedures for online maintenance. Detailed procedures shall be submitted by the Contractor for approval by the Engineer.

The Contractor’s control and instrumentation system structure, the redundancy concept and the allocation of plant and equipment to Automation Units (AU), shall be submitted to the Engineer for approval as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

The Contractor shall install shall computer based equipment (computers and servers) in a cubicle in an environmentally controlled area. All computer equipment shall be 19” rack mounted, no desktop type computers shall be utilised.

3.2.3.5.4.2 PROCESS COMMUNICATION BUS SYSTEMS

The process communication bus systems shall provide the data link between all elements of the control and instrumentation system including the control and instrumentation system cubicles, the operator workstations, the Engineering and Diagnostic workstations, the local control panels (LCP), the asset management system and the plant information system.

The process communication bus systems shall in all instances be dual redundant providing maximum availability of the overall system communications. The process communication bus systems shall be capable of operating over point to point distances of at least 10 km in some areas. Fibre optic technology shall be provided for the inter-connection between all systems not located in the same room. Co-axial cables could be allowed for use for the inter-connection between systems located in the same room. Redundant buses shall be run in different physical routes. The transfer to the back-up communications channel shall be bump-less, seamless and without operator intervention and without disrupting the system operation.

The bus systems shall include all bus interfaces, bus couplers and bus controllers and shall be configured with adequate redundancy such that the bus system availability and reliability is higher than that of the control and instrumentation system. The process communication network shall meet all response criteria and shall not cause data to be lost



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or the system to lose control upon failure and subsequent transfer to the redundant path. Bus faults or loss of redundancy shall be alarmed, identifying the the error or error type and bus area where the fault occurred

The error detection and correction capabilities of the network shall make the system fault tolerant but without any degradation of response times and system reliability.

In the event of a process communication bus or an operator workstation system failure, local manual control mode shall automatically be reverted to where provided in the plant. The local control station’s operation shall be activated via the selector switch on the respective local control stations as defined in the technical guideline, EED_GTD_C&I_007 in Appendix 14 – Project Standards.

Appendix F contains conceptual architectural drawings, descriptions, fault behaviour and bus speeds. Further architecture definition and complete design shall be submitted during project System Engineering by the Contractor for approval by the Engineer.

3.2.3.5.4.3 FUNCTIONAL DISTRIBUTION

The various Plant Areas shall be controlled from a number of independent controllers called Automation Units.

Each Automation Unit (AU) shall be fully self-contained in order to:

• Perform data acquisition from HART protocol field transmitters and other field devices

• Perform signal validation, conditioning and processing

• Execute control algorithms for analogue and binary control

• Actuate field devices

• Link to the process communication bus system

The plant configuration and process redundancy shall be taken into account in the design of the control and instrumentation system structure. The Contractor shall optimise the allocation of plant and equipment to AU’s, functional distribution, while maintaining the integrity of the mechanical plant’s redundancy. The failure of any AU or other control and instrumentation equipment cubicle shall not cause the failure of two or more mechanical sub-systems that are configured redundantly, e.g. the failure of one AU shall not cause the failure of more than one demineralisation train, more than one CPP regeneration train, or both the Draft Groups.

No common mode of failure shall exist between AU’s. The AU’s shall be distributed throughout the various sections of the plant. The AU’s shall be housed in cabinets in the control and instrumentation equipment rooms for the Power Islands and the sub-station rooms for the Balance of Plant areas.

3.2.3.5.4.4 REDUNDANCY

The redundancy of functions within Automation Units and hardware modules shall be to the reliability, availability and maintainability levels as defined in section 3.2.3.5.1.

The Boiler Protection system requires particular minimum redundancy as specified in section 3.2.3.5.4.7.4.

As a minimum all AU processors shall be configured redundantly. Redundant processors and modules shall be capable of being replaced on-line with no effect on the operating



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plant. The redundancy scheme shall be self-monitoring and uses diagnostics to prevent switching to the slave (standby) Automation Unit processor if there is a problem with any of the redundancy hardware.

The transfer from master Automation Unit processor to the slave Automation Unit processor shall be seamless.

Where power supplies are required to an AU or cubicle they shall be redundant and hot exchangeable.

The Plant Information System servers shall be physically and spatially separated.

3.2.3.5.4.5 DATA ACQUISITION

The data acquisition of the control and instrumentation system shall provide for the processing of signals from field mounted transmitters and other field or interfacing devices such that all requirements of the Works, including that of an integrated management system (refer to clause 3.2.3.5.4.9), are complied with.

The Data Acquisition system shall provide for transmitters and for the interrogation of contacts. The Data Acquisition system shall monitor the condition of the measurements, faults and other diagnostic information reported by the transmitters.

The Data Acquisition system shall continuously checked for validity of all analogue and digital measurement signals.

Signal distribution and transmission to other systems requiring the measurements, fault and diagnostic data, shall be done as part of the Data Acquisition system. The Data Acquisition systems shall be contained within the AU’s. No additional and or separate hardware shall be required for the data acquisition for other systems including the integrated Asset Management system.

Time stamping shall be done at the lowest level and at the source of the signal (refer to clause 0).

Data Acquisition system time stamping shall be synchronised to the station master clock Input Signal Conditioning

The system shall provide for all types of inputs signals from the field.

Analogue input measurements, with the exception of humidity transmitters, position transmitters, vibration and seismic sensors, from the field are based on two-wire 24 V DC, 4 - 20 mA signals with HART protocol and as indicated in Appendix 4 – Instrument Schedule and Appendix 9 – Limits of Supply and Services. Any supply of devices without HART protocol shall be for the approval of the Engineer.

All Binary input signals from field devices shall be based on three-wire, change over contacts, except where explicitly stated otherwise. All field contacts shall be interrogated using 24 V DC.

Data Validation

All analogue and digital signals shall be continuously monitored for validity, whether used for operator information, control, protection, interlocking, calculations or plant history.



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Data shall be specifically checked for validity after power supply dips / interruptions and any system / component failures or irregular modes of operation.

Data validation shall be an integral part of the control & automation system’s functions.

Data validation shall include:

• signals monitored for wire break (change over contacts),

• out-of-range values,

• same measurement discrepancies

• abnormal rate-of-change,

• contact bounce,

• invalid process operating ranges

• power supply failure,

• card removal,

• out-of-scan,

• simulated inputs,

• short circuit,

• pole disagreement (changeover binary contacts).

All signals shall have data quality attributes of good, bad, out-of-scan and substituted value which shall be carried forward to the control and instrumentation system, operator interface, information system, historian and engineering / diagnostic / commissioning workstations.

Scan Cycles

The Contractor shall provide high-speed scan cycles for areas identified by the Contractor where plant operation and control requires it.

Binary signals that initiate a trip or load loss shall be captured with a time resolution and accuracy such that they can be identified in a post event review.

All binary signals in the Balance of Plant electrical reticulation system and Power Island electrical reticulation system (function groups EFG01 and EFG02) shall be monitored for status changes at source on a priority interrupt basis to provide a time stamping resolution of 1 ms or better except for those signals captured via the radio link and Profibus interfaces.

The Contractor shall optimise the scan cycles in order to match the process control and operating requirements. The Contractor shall submit the scan cycle optimisation report to the Engineer for approval.

3.2.3.5.4.5.1 OUTPUT SIGNALS

For all actuators the control and instrumentation system output shall be directly connected to the integral switchgear of the actuator.

For drives the control and instrumentation system shall initiate the interposing relays.



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Solenoid valves shall be initiated directly by the output cards of the control and instrumentation system.

The Contractor shall ensure that the 24 V DC SOV’s for all pneumatic valves are able to open and close within a maximum time of 100 ms.

3.2.3.5.4.5.2 SWITCHGEAR CAPABILITIES

All digital control and instrumentation system output cards (drive cards) shall be able to switch the following directly:

• The pull in current is 120 mA and the hold in current is 100 mA

• The voltage is 24 V DC and the relay dropout voltage is 17 V DC

3.2.3.5.4.5.3 GALVANIC ISOLATION

The Contractor shall provide galvanic isolation at the source of the signal or at the interface between the Contractor’s and Other Project Contractor’s control and instrumentation systems.

3.2.3.5.4.6 TIME SYNCHRONISATION

The Contractor shall provide a suitable method of time synchronisation for all the relevant components of the control and instrumentation system for the complete power plant. This shall include for time stamping of control and instrumentation systems provided by Other Project Contractors.

The Contractor shall supply a redundant GPS-based system (including antennae) with a data string protocol and any interface equipment required to synchronise the entire control and instrumentation system of the Works and those supplied by Other Project Contractor’s, according to the local time offset with relation to GPS time. The time systems interface outputs shall be configured such that it is separate for each of the Power Islands and the Outside Plant such that there is no common mode of failure or interference between the sets of outputs. In the event of a failure of one clock the redundant clock shall resume the time synchronised function automatically, seamless and without maintenance intervention.

The essential characteristics of this system shall be:

• Time synchronisation for all measurements shall be at the source.

• A time accuracy of 1 ms or better across the entire control and instrumentation system, and in case of loss of the GPS, the maximum permissible time drift does not exceed the rate of 1.8 ms per day.

• The system determines its installation position automatically, i.e. if no data with regards to position co-ordinates, time, calendar and ephemera’s are known, i.e. the system is self-calibrating

• The system’s power supply is provided by the Contractor’s UPS. The power supply shall be designed to allow individual unit UPS’s to be switched off without affecting the common clock. Voltage variations do not affect the system’s integrity in any way.

• The system shall retain critical data (by means of non-volatile memory or battery back-up) in the event of power supply failure not exceeding 1 hour. If power is restored within this given time, the system shall become fully operational (according to the accuracy requirements) within 5 minutes from restoration of power



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• Time synchronisation to the plant, after recovery of the GPS clock, after a failure shall be automatic.

As a minimum, the Contractor shall provide time synchronisation to the GPS based system for the following systems:

• Generator protection system

• Generator fault recorders

• Generator synchroniser system

• Generator Condition Monitoring system

• Turbine Supervisory system

• Turbine Protection & Control and instrumentation system

• Vibration Analysis system

• Boiler Condition Monitor

• Boiler Protection System

• Furnace Cleaning Expert systems

• Sootblower Expert system

• Laboratory Expert system

• AGC ERTU

• AVR

• Energy Metering Systems

• Fire Detection System

• Building Management System

Appendix D contains typical drawings and descriptions of the conceptual time synchronisation system. Further architecture definition and complete design shall be submitted during project System Engineering by the Contractor for approval by the Engineer.

3.2.3.5.4.7 BOILER CONTROL AND SAFETY SYSTEM

3.2.3.5.4.7.1 GENERAL

The Boiler control and safety system consists of three integrated and co-ordinated subsystems in order to minimise the risk of damage to plant and personnel. The three subsystems are:

• Boiler Control and instrumentation system

• Burner management system

• Boiler protection system (BPS)

Each of the three subsystems shall be regarded as part of the total protection and safety philosophy. Operational and maintenance procedures shall be considered in the design of the Boiler Control and Safety system.



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3.2.3.5.4.7.2 ROLE OF CONTROL IN BOILER SAFETY

In the context of the Boiler safety system, the control and instrumentation system shall be designed to guide the plant away from potentially dangerous and uncontrollable conditions. The measures taken shall include correct sequencing of plant start up (interlocking), robust controls, and validation of measurements and cross correlation between measured process parameters.

The control and instrumentation system shall provide the overall co-ordination between all elements of the Boiler protection and safety system. The control and instrumentation system provides the following safety related functions as part of its normal functions:

• Automatic start-up and shutdown of standby plant in a safe, fast and co-ordinated manner thereby limiting major plant disturbances or threats

• Control of auxiliary plant to prevent damage to main plant components

• Interlock logic, ensuring that the capability of all plant is properly matched thus preventing the Power Island from reaching potentially hazardous conditions.

3.2.3.5.4.7.3 BURNER MANAGEMENT SYSTEM

The burner management system is an integral part of the Power Island control and instrumentation system and is part of the overall Boiler safety system. The burner management system shall prevent the operator or the automatic controls from allowing the Power Island to be operated in a potentially unsafe condition. The main function of the burner management system is the start up and shutdown of the fuel oil burners and the PF burners. The burner management system shall consist of all the interlocks and co-ordination necessary between the different fuel systems. These systems are the ignition system (Gas and HT spark), the fuel oil system and the pulverised fuel (coal) system.

3.2.3.5.4.7.4 BOILER PROTECTION SYSTEM

The Boiler protection system is the kernel of the safety system and is regarded as the last line of defence in the safety function of the Power Island. The control and instrumentation system and the burner management system, in principle shall never allow the plant to achieve a state where the boiler protection system is required to operate.

The BPS shall be designed to trip all plant that is necessary to prevent damage or minimise damage in the event of unsafe conditions being detected by the instrumentation that form part of the Boiler protection system.

The BPS shall be a separate and proven failsafe system. As a minimum the system shall be provided, configured and installed as a SIL 3 compliant system in accordance with IEC 61511. Redundancy shall be at least 2-o-o-3 for the boiler protection system.

The BPS shall be able to be functionally tested by the operator from the operator workstation.

The functional requirement to which the system is designed is based on the following standard / codes in Appendix 14 – Project Standards:

• Eskom PF Firing Regulations (PFFR) GGR 0568

• NFPA 85



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Appendix C contains typical drawings and descriptions of the conceptual boiler protection system. Further architecture definition and complete design shall be submitted during project System Engineering by the Contractor for approval by the Engineer.

3.2.3.5.4.7.5 BOILER TUBE WALL TEMPERATURE MONITORING AND BOILER LIFETIME MONITOR

The Contractor shall implement the Boiler Tube Wall Temperature Monitoring as part of the Works according to LOSS_P02_SUP1 in Appendix 9 – Limits of Supply and Services. The Engineer will provide the stress algorithms specifications in consultation with Other Project Contractors during the system engineering phase.

The Contractor shall integrate to the Boiler Lifetime Monitor according to LOSS_P02_SUP2 in Appendix 9 – Limits of Supply and Services.

3.2.3.5.4.8 ALARM MANAGEMENT SYSTEM

The Contractor shall develop and provide an Alarm Management System (AMS) that will meet the performance requirements specified in Appendix 15 – Minimum Assessment and Testing RequirementsAppendix 15 – Minimum Assessment and Testing Requirements. The Contractor shall select and rationalise all alarms according to the Eskom Guideline EED_GTD_C&I_006 and GGPP1511. The Contractor shall provide documentation on the alarm management process used and on the alarm rationalisation process used as per Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

As a minimum, the alarm management shall:

• Supply complete library of filters, deadbands, time delays to process the analogue inputs.

• Supply curves, trends, logs (periodic and on demand), calculations modules, alarms grouping and eclipsing functionalities.

• Supply a flexible number of alarm priorities and associated colors.

• Provide operators alarm lists, filterable on each column and by priority.

• Associated with each alarm: direct-call views, on-line help, alarm sheet procedure, and operator’s comments file.

• Allow suppression on state-based criteria or shelving by operator.

• Allow alarm acknowledgement one by one, page by page, or on mimics.

• Supply a configurable alarms analysis module (Advanced Alarm Management).

• Provide a key performance metrics module.

• Supply an alarm data collector (Master alarm database).

Appendix K contains typical documentation on the Advanced Alarm Management tool. Complete Alarm Management functionality and documentation shall be submitted by the Contractor for approval by the Engineer during System Engineering.

3.2.3.5.4.9 ASSET MANAGEMENT SYSTEM

The Contractor shall supply a control and instrumentation asset management system that incorporates all HART enabled equipment information via the 4-20mA HART interface. This information is acquired via the control and instrumentation system standard input and output cards without the requirement for additional hardware. All analogue input and output cards of the DCS MFC 3000 shall be HART enabled.



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The asset management system shall provide the means to be able to do condition based maintenance on the HART enabled equipment. The asset management system shall be linked to the control and instrumentation maintenance procedures and processes provided by the Contractor in order to form an integrated condition based maintenance regime for the control and instrumentation equipment.

The asset management system shall further be linked to the data validation in order to provide an integrated measurement and data storage quality verification system. The asset management system shall also contain all the field instrumentation calibration data sheets. These data sheets shall be updated automatically after calibration and shall be digitally signed.

Appendix L contains typical documentation on the Asset Management system. Complete Asset Management functionality and documentation shall be submitted by the Contractor for approval by the Engineer during System Engineering.

3.2.3.5.5 CONTROL / ENGINEERING / DIAGNOSTICS / COMMISSIONING ROOMS

3.2.3.5.5.1 POWER ISLAND CONTROL SUITE (PICS) FACILITIES

The six Power Island and Station Electrical Reticulation shall be controlled from a single centralised Power Island Control Suite. Space for this room has been allocated by the Engineer in the Auxiliary Bay 16m level according to drawing 0.84/501 in Appendix 12 – Project Drawings. The PICS should house three control area’s, adequately spaced to accommodate all operating activities for the following:

• Control of Power Island 1 to 3 and CCTV monitoring per Power Island.

• The EOD (control of the Station Power Reticulation), iBMS and CCTV monitoring and control and electrical engineering workstation with two 21” monitors.

• Control of Power Island 4 to 6 and CCTV monitoring per Power Island

The design of the three operating areas shall be such that it will control traffic to the PICS without losing the operating efficiency benefits gained from the control centralisation concept.

The Contractor shall provide the following in the PICS:

• Six Power Island operator workstations (as defined in section 3.2.2.2 and Figure 10Figure 10) – 1 per Power Island with space accommodation for two operators.

• One EOD Operator workstation (as defined in section 3.2.2.2 and Figure 11Figure 11)

• Shift supervisor workstation (same configuration as engineering workstation as defined in section 3.2.2.2 and Figure 12Figure 12)

• Engineering workstation(s) per Power Island (as defined in section 3.2.2.2 and Figure 12Figure 12)

• Ergonomics and work flow studies

• The design and furniture for all other Control Suite facilities as specified in GGM 1365 (simulator suite, smokers’ room, ablution, offices, conference rooms, permit rooms). Some of these areas will be outside the allocated PICS area – refer to drawing 0.84/501.



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• Design space for one office computer per operator station

• Design space for a CCTV viewing facility per operator station

• Design space for the electrical engineering workstation including two 21” monitors

3.2.3.5.5.2 BALANCE OF PLANT CONTROL SUITE (BOPCS) FACILITIES

The Balance of Plant (coal, ash, H2 plant, N2 plant, Fuel oil and Low Pressure Services) and Water Treatment Plant shall be controlled from a single Balance of Plant Control Suite (BOPCS) located in the Station Services Building (SSB) according to space allocated by the Engineer in drawing 0.84/908 in Appendix 12 – Project Drawings

The Employer shall provide space in the SSB for the BOPCS. The Contractor shall provide the following in the BOPCS:

• One WTP Operation Workstation (same configuration as Power Island operator workstation as defined in section 3.2.2.2 and Figure 10Figure 10)

• One Materials Handling and LPS operator workstation (same configuration as Power Island operator workstation as defined in section 3.2.2.2 and Figure 10Figure 10)

• Two engineering workstations (as defined in section 3.2.2.2 and Figure 12Figure 12). One for the WTP and one for the Materials handling and LPS area.

• Sufficient space only for an iBMS workstation capable of controlling and monitoring the iBMS for the complete power plant including CCTV monitoring and controlling capabilities


• The design and furniture for all other Control Suite facilities as specified in GGM 1365 (smokers’ room, ablution, offices, conference rooms, permit rooms). some of these areas will be outside allocated PICS area – refer to drawing 0.84/501



3.2.3.5.5.3 WATER TREATMENT PLANT REMOTE CONTROL PANEL (WTPRCP) FACILITIES

The Water Treatment Plant shall have a local control workstation located in the WTP Building according to space allocated by the Engineer in drawing 0.84/641

The Employer shall provide space in the WTP for the WTPRCP. The Contractor shall provide the following in the WTPRCP:

• One WTP Operation Workstation (same configuration as Power Island operator workstation as defined in section 3.2.2.2 and Figure 10Figure 10)



3.2.3.5.5.4 TEMPORARY STATION CONTROL SUITE AND TEMPORARY COMMISSIONING ROOM (SCS-TEMP)

Due to the sequencing of building the Power Island and the auxiliary bay, the permanent PICS located between Power Island 3 and Power Island 4 will not be ready for operational activities for Power Island 6, Power Island 5 and possibly Power Island 4. The Engineer



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shall make provision for space in the auxiliary bay 16m level at Power Island 6 (between columns 73 and 76) for a Temporary Station Control Suite and Temporary Commissioning Room (SCS-TEMP). Refer to drawing 0.84/501 Sheet 6 in Appendix 12 – Project Drawings.

The Contractor shall furnish the SCS-TEMP to the same quality of finish and installation as for the permanent control room. All cabling, lighting, furniture and plant and equipment shall be installed to the same standard as for permanent usage. Reliability and availability of equipment shall not be compromised by the temporary installation. Relocation of the Power Island operating functions to the permanent control room shall not result in a plant shutdown. Equipment for the permanent control room shall be completely installed while operation is still being done from the SCS-TEMP. The moving of the operating function from the SCS-TEMP to the permanent control room shall only require logging in at the new location. The Contractor shall create a control room hot-changeover plan during the detailed design phase that defines the specific steps and requirements necessary to transfer plant control from the SCS-TEMP to the PICS.

The Contractor shall make provision for the control and operating of at least the first two Power Islands and the station electrical reticulation (EOD). The Contractor shall make provision for the Commissioning activities for at least the first three Power Islands and the station electrical reticulation (EOD) from the SCS-TEMP. The Contractor shall optimise the planning of the utilisation of the temporary and permanent control suite such that no commissioning activities will take place in the permanent control suite and that the operating activities in the temporary control suite is minimised in order to ensure that commissioning activities does not disturb the operation of commercially operational Power Island.

The Contractor shall provide the following in the SCS-TEMP:

• Two Power Island Operator workstations (as defined in section 3.2.2.2 and Figure 10Figure 10), configured to operate any of Power Island 1 to Power Island 6.


• Shift supervisor workstation (same configuration as engineering workstation as defined in section 3.2.2.2 and Figure 12Figure 12)

• Three engineering/commissioning workstations configured to Engineer any of Power Island 1 and Power Island 6 and the EOD (as defined in section 3.2.2.2 and Figure 12Figure 12).

• Facility for a temporary permitting system for at least three Power Islands


• The design and furniture for all other Control Suite facilities as specified in GGM 1365 (smokers’ room, ablution, offices, conference rooms, permit rooms). some of these areas will be outside allocated PICS area – refer to drawing 0.84/501

• Design space for one office computer per Operator & Engineering workstation


• Design space for an electrical engineering workstation with two 21” monitors

3.2.3.5.5.5 POWER ISLAND 4-6 AND EOD ENGINEERING / DIAGNOSTICS AND COMMISSIONING ROOM (EDCR4-6) FACILITIES

After the commissioning and operating activities have been completed in the SCS-TEMP the Contractor shall convert the SCS-TEMP into the permanent engineering, diagnostic



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and commissioning room for Power Island 4-6 and the EOD (EDCR4-6). HMI equipment from the SCS-TEMP that is not required for the EDRC4-6 can be utilised in the EDRC1-3 subject to the Engineer’s approval. The Contractor shall provide the following in the EDCR4-6:

• One Power Island operator workstations (as defined in section 3.2.2.2 and Figure 10Figure 10), configurable to operate / commission / engineer any of Power Island 4, Power Island 5 or Power Island 6


• Three engineering and diagnostic workstations configured to engineer Power Island 4, Power Island 5 or Power Island 6 and the EOD (as defined in section 3.2.2.2 and Figure 12Figure 12).


• The design and furniture for all other Control Suite facilities as specified in GGM 1365 (simulator suite, smokers’ room, ablution, offices, conference rooms, permit rooms). Some of these areas will be outside allocated PICS area – refer to drawing 0.84/501

• Design space for one office computer per operator and engineering workstation

• Design space for a CCTV viewing station


3.2.3.5.5.6 POWER ISLAND 1-3 ENGINEERING / DIAGNOSTICS AND COMMISSIONING ROOM (EDCR1-3) FACILITIES

The Contractor shall provide for the permanent engineering, diagnostic and commissioning room for Power Island 1-3 (EDCR1-3). The Employer shall provide space in the auxiliary bay 16m level at Power Island 2 for the EDCR1-3. The Contractor provides the following in the EDCR1-3:

• One Power Island Operator workstations (as defined in section 3.2.2.2 and Figure 10Figure 10), configurable to operate/commission/engineer any of Power Island 1, Power Island 2 or Power Island 3

• Three engineering workstations configured to engineer Power Island 1, Power Island 2 or Power Island 3 and the EOD (as defined in section 3.2.2.2 and Figure 12Figure 12).


• The design and furniture for all other Control Suite facilities as specified in GGM 1365 (simulator suite, smokers’ room, ablution, offices, conference rooms, permit rooms). Some of these areas will be outside allocated PICS area – refer to drawing 0.84/501.

• Design space for one office computer per operator and engineering workstation

• Design space for a CCTV viewing station




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3.2.3.5.5.7 TEMPORARY AND PERMANENT CONTROL SUITES, WATER

TREATMENT REMOTE CONTROL PANEL AND TEMPORARY AND PERMANENT EDCR DESIGN REQUIREMENTS

Each control suite, WTPRCP and EDCR shall house all necessary support systems and hardware, such as documentation, Zippel storage cabinets, references, procedures and computerised support systems necessary for the execution of the operators, engineers and maintenance staff duties. The operators shall be able to access all necessary documentation such as operating procedures, alarm cards and similar reference documents electronically in the control suite, with paper based documents stored in close proximity of the control rooms. Printers shall be provided at each control room for logs, reports and hard copies of displays and other documents on request by the operators, engineers and maintenance personnel.

The entire room environment shall be designed with due consideration to human factors, ergonomics, safety, access, shift work, and interpersonal communications.

The Contractor shall provide the design of the control rooms in accordance with the ergonomic requirements of GGM1365 and environmental conditions of GGS1426 in Appendix 14 – Project Standards. The Contractor shall further submit an Ergonomics Study and Human Work Flow Study Report to the Engineer for approval. The Contractor shall conform to the Employer’s Corporate Identity requirements as identified in Appendix 14 – Project StandardsAppendix 14 – Project Standards.

The Contractor’s design shall include the following:

• Lighting and luminaries requirements (normal and emergency)

• Small power requirements

• Electrical plug points

• Channelling for cabling

• Position of equipment and hardware

• Provision of Telephones for each operating desk area

• Air conditioning heating and cooling loads

• Any special isolation from electromagnetic interference.

• Provision of LAN connections at each operating desk area

• Sound suppression

• Interior space allocation and architectural details

The Contractor shall submit design documents for the Control Rooms and EDCRs as defined in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

All desks shall be custom designed, suitable for mounting the operating display devices required by the respective operator and engineering and diagnostic workstations. The desk surface height shall be electrically adjustable by the operator. The display screen (HMI) height above the desk surface shall be manually adjustable. The desk surfaces shall provide space for writing as well as space for one telephone and intercom / handheld radio base station per operator. Each desk shall contain a facility for the storage of the keyboard such that it does not interfere with the operator’s working area when it is not in use. A set of matching desk drawers shall be provided for each operator. Desks shall be durable, robust and suitably matched to the furniture and control room décor. All



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desk surfaces shall be at least 32mm thick and the surface temperature shall be neutral to touch.

All furniture shall be of the modular office type, and is of a robust design clad in industrial type fabric suitable for the environment in which it is used (i.e. continuous use 24 hours per day) and is in accordance with the Employer’s corporate identity standards as per the specification, Appendix 14 – Project Standards.

The final design and layout of the desks, furniture and panels shall be discussed and clarified during the system engineering phase (technical clarification meetings) and provided to the Engineer for approval.

Any cooling requirements on the control desks shall be achieved without the use of fans.

All operator control room facilities, in conjunction with the control and instrumentation system, shall enable the operator to operate the plant in all control modes and under all abnormal and emergency conditions without challenging the operator’s abilities to adequately cope with the situation. The operator shall at all times be fully cognisant of the plant’s status and trends (situational awareness) and is able to observe the control and instrumentation system’s status, operation and integrity.

Appendix M contains typical conceptual design details for control room areas. Specific design details and layout arrangements shall be submitted for approval to the Engineer during System Engineering.

3.2.3.5.5.7.1 POWER ISLAND CONTROL SUITE (PICS) DESIGN REQUIREMENTS

General

Simultaneous start-up of multiple Power Islands shall be incorporated into the design. The six individual Power Islands shall be controlled from the PICS and include all operations including start-up, shutdown, load control, transient and emergency situations.

The Contractor shall include for the design, supply and installation of the furniture as listed below.

• Six Power Island Control Desks,

• One Control Desk for the SER operator,

• Sixteen Operator Chairs

• Six Printer Stands

• Fourteen Filing and Storage Units

• Fifty Lockers for operators

Power Island Workstations and Desks Configuration

The desk configuration is such that three Power Island are adjacent and one operator can operate each Power Island, but it shall be designed that one operator can operate all three Power Island during stable normal operation.

The operator interface shall be via a set of operating displays units (as defined in section 3.2.2.2) arranged such that each Power Island operator shall be able to operate a single integrated boiler / turbine / generator unit.



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Each Power Island operator workstation shall have a minimum of twelve operating display units and three operator display processors. Each operator display processor shall have the capability of driving four display units.

Three independent and concurrent operations with associated input devices shall be possible. Failure of one operator processor shall limit the loss to one operator input and four operator display units. The functionality of switching the display units connected to the operator processor with four display units to any of the operator processors with the two spare display unit outputs shall therefore be possible. Refer to Figure 10.

Keyboard Mouse

Engineering display processor

Operator Station Configuration

Keyboard Mouse


Keyboard Mouse


Figure 10: Power Island Operator Station configuration

The Contractor shall supply and install hardwired push buttons, with covers to prevent accidental activation, on the Power Island control desks for the following:

• Boiler master manual trip

• Turbine manual emergency trip

• Turbine Fire trip

• Turbine Physical Over-speed selection

• Reheat Safety Valves open

• HP Bypass Valve Quick open

EOD Workstation and Desks Configuration



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The EOD operator workstation shall have a minimum of twelve operating display units, two information display units and five operator display processors. Each operator display processor shall have the capability of driving four display units.

Three independent and concurrent operations with associated input devices shall be possible. Failure of one operator processor shall limit the loss to one operator input and four operator display units. Failure of one operator information processor shall limit the loss to one operator input and one operator information display units. Refer to Figure 11.

Keyboard Mouse

Engineering displayprocessor

EOD Operation Station Configuration

Keyboard Mouse


Keyboard Mouse


Keyboard Mouse


Keyboard Mouse


Operator Information Display Units

Operator Information Display Units

Operator Display Units



Figure 11: EOD Operator Station configuration

The EOD operator workstation HMI shall have the functionality to tag isolated / earthed breakers / feeders and have an overview mimic giving the status of all breakers/feeders.

The Contractor shall provide a system clock, a master clock and a differential clock display units to the EOD operator.

The Contractor shall provide a system clock and a master clock in the control room area of Power Island 1 to 3 visible from all three operator stations.



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The Contractor shall provide a system clock and a master clock in the control room area of Power Island 4 to 6 visible from all three operator stations.

3.2.3.5.5.7.2 BALANCE OF PLANT CONTROL SUITE (BOPCS) DESIGN REQUIREMENTS

BOPCS Workstations and Desks Configuration

The BOPCS operator interface shall be divided into the WTP operator workstation and the Materials Handling and LPS operator works station.

The WTP operator workstation shall have a minimum of twelve operating display units and three operator display processors. Each operator display processor shall be connected to four display units.

Three independent and concurrent operations (WTP) with associated input devices shall be possible. Failure of one operator processor shall limit the loss to one operator input and four operator display units. The WTP operator workstation configuration shall be the same as the Power Island operator workstation of Figure 10.

The Materials Handling and LPS operator workstation shall have a minimum of twelve operating display units and three operator display processors. Each operator display processor shall be connected to four display units.

Three independent and concurrent operations (Materials Handling and LPS) with associated input devices shall be possible. Failure of one operator processor shall limit the loss to one operator input and four operator display units. The Materials Handling and LPS operator workstation configuration shall be the same as the Power Island operator workstation of Figure 10.

Balance of Plant Desks and Furniture


• One Utilities Plant Control Desk

• Six Operator Chairs

• Three Printer Stands

• Five Filing and Storage Units

• Twenty Lockers for operators

3.2.3.5.5.7.3 WATER TREATMENT PLANT REMOTE CONTROL PANEL DESIGN REQUIREMENTS

WTPRCP Workstation Configuration

WTPRCP operator workstation shall have a minimum of twelve operating display units and three operator display processors. Each operator display processor shall be connected to four display units.

Three independent and concurrent operations with associated input devices shall be possible. Failure of one operator processor shall limit the loss to one operator input and four operator display units. Refer to Figure 10.



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WTPRCP Desks and Furniture


• One WTP Control Desk

• Three Operator Chairs

• Two Printer Stands

• Two Filing and Storage Units

• Five Lockers for operators

3.2.3.5.5.7.4 PERMANENT ENGINEERING / DIAGNOSTIC / COMMISSIONING ROOMS (EDCR1-3 & EDCR4-6) DESIGN REQUIREMENTS

Workstations and Desk Configuration

Each operator workstation shall have a minimum of eight operating display units and three operator display processors. Each operator display processor shall have the capability of driving four display units. One operator display processor shall be connected to four operator display units and two operator processor units to two operator display units.

Three independent and concurrent operations with associated input devices shall be possible. Failure of one operator processor shall limit the loss to one operator input and two operator display units. The functionality of switching the display units connected to the operator processor with four display units to any of the operator processors with the two spare display unit outputs shall therefore be possible. Refer to Figure 10.

Each engineering/commissioning workstation shall have a minimum of two operating display units and one operator display processor configured to allow one operation to be undertaken by the engineer/operator with one pointing device.

Desk and Furniture

The Contractor shall include for the design, supply and installation of the furniture as listed below in both the EDCR1-3 & EDCR4-6.

• One Operator desk

• Four Engineering Desks

• Ten Operator Chairs

• Three Printer Stands

• Five Filing and Storage Units

• Ten Lockers for Engineers / commissioners

• 3 Zippels

3.2.3.5.5.8 CONTROL ROOMS AND EDCR PRINTING REQUIREMENTS

3.2.3.5.5.8.1 GENERAL

Three Network monochrome printers and three network colour printers shall be provided in the PICS.



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Two Network monochrome printers and two network colour printers shall be provided in the BOPCS.

One Network monochrome printer and one network colour printer shall be provided in the WTPRCP.

One Network monochrome printer and two network colour printers shall be provided in the SCS-TEMP and can be utilised for the EDCRC4-6 if serviceable.

One Network monochrome printer and two network colour printers shall be provided in the EDCRC1-3.

One Network monochrome printer and one network colour printer shall be provided in each of the Power Island Equipment Rooms, the SSB Equipment Room and the WTP Equipment Room.

As a minimum, all printers provided by the Contractor shall be laser printers with A3 and A4 printing capabilities.

3.2.3.5.5.8.2 PRINTER STANDS

Suitable tables or stands, subject to approval by the Engineer, shall be provided for all the printers. Provision shall be made for the enclosed and lockable storage of the paper supplies and printouts.

3.2.3.5.6 OPERATOR WORKSTATIONS

3.2.3.5.6.1 GENERAL

The operator workstation is the primary interface of the plant operating personnel. Information from the different plant areas shall not be restricted to any one operator workstation (limited to 5 simultanous access per Power Island / BOP control network), i.e. the entire plant can be monitored and observed from any one operator workstation. No additional passwords or access control of any form shall be required by an operator to monitor any section of the plant. The software licensing shall be unlimited licences and shall not require installation codes after initial installation.

The operator control interface shall present an integrated and standardised set of graphics, displays and facilities which shall be designed to and conform to ergonomic principles and modern power plant practice. The design approach of the operating interfaces, and the underlying functionality of the control and automation system behind the interfaces, shall be consistent across all systems and functional areas. It shall be possible for the operator to open multiple windows simultaneously on the same display unit.

Specific attention shall be given to the EEMUA publication 191 during the plant design and optimisation phase to prevent alarm overload during normal and transient conditions.

A comprehensive and integrated alarm handing system shall be employed, which clearly distinguishes between different alarm types. Alarm information shall not be lost or inaccessible whilst navigating through displays, and alarm presentation shall dynamically provide the operator with information matched to the current situation and its criticality.

Displays shall be configured in a clear and unambiguous manner to provide the operator with information relevant to the task. Icons and symbols shall be used consistently



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throughout the displays for all units. Symbols of plant in low level displays may be based on outline or physical structure of the plant device if ergonomically appropriate.

The operating functionality of the operator workstations shall be restricted to authorised personnel only by means of a multilevel password system. A plant area shall be operated from only the operator workstation dedicated to that plant area in the control room with viewing privileges to view any other plant area. The operator work stations in the EDCR shall only be able to operate plant related to that EDCR with viewing privileges for the engineering and diagnostic workstations. It shall not be possible to operate a plant area (e.g. PI1, PI6, BOP) from more than one operator station simultaneously. Selection of the operator workstation to operate the plant area shall be controlled by HMI inputs to the operator workstation that, under normal conditions, controls that plant area.

Each operating display unit functions independently from all other operating display units forming part of the applicable operator workstation. Any one operating display unit can serve as a fully functioning interface for the plant operator. Thus failure of any operating display unit does not inhibit plant operation.

The operator workstation shall be configured such that it supports on-line maintenance, i.e. faulty display units, pointing devices, etc can be replaced without re-initiating or re-booting the operator workstation. The operating display units shall not lock-up under any circumstance.

A fully functional HMI that includes control functionality, indication, alarming, trending, on-line plant performance information and event recording shall be provided for the Operator Workstations.

The Contractor shall provide the HMI in accordance with the technical guideline, EED_GTD_C&I_002 in Appendix 14 – Project Standards. The process response time for process displays update, for analog variables shall not exceed 1.5 seconds.

Set point and actual values shall both be indicated where applicable. Selection of any HMI display graphic shall not require more than two keystrokes. In alarm or abnormal conditions, not more than one keystroke shall be required to navigate to the relevant display. Binary sequence logic shall be displayed dynamically using functional logic diagrams.

The colour coding for the EOD mimics shall conform to NRS 040 part 2.

3.2.3.5.6.2 OPERATOR DATA

A minimum of 6 months daily operating data shall be available to plant operators through the operator workstations.

The operator workstation shall provide the operator with ability to view all reports generated by the control and instrumentation system.

Logs and their calculated values shall be retained in the database.

All information available to the operator from the HMI system shall be printable on demand only. The facility to print user-defined hardcopies of specific occurrence shall form an integral part of the system.

All operator faceplates for actuators shall display the actual position and operating time.



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3.2.3.5.6.3 CALCULATED VALUES (COMPOSED VALUES)

The system shall perform calculations on process variables to create new calculated data values, and these shall be retained in the database.

The calculated data values once retained in the respective databases can be accessed and manipulated as any other data points.

Calculations shall to include mathematical and statistical functions.

Calculations can be suspended or substituted when plant conditions lead to invalid results. Invalid results shall be flagged to the operator.

The steam tables shall be used to obtain the steam properties including enthalpy and entropies. Steam tables shall be available for use by any user defined routines.

If calculations use values that are bad, missing or substituted, this shall be flagged in the system.

Building, changing or configuring of calculation functions shall be possible by means of a high level interactive interface.

3.2.3.5.7 ENGINEERING AND DIAGNOSTIC WORKSTATIONS

3.2.3.5.7.1 GENERAL

The engineering and diagnostic workstation is an integrated system providing facilities for the full application engineering of all areas of the control and instrumentation system. The diagnostic and maintenance facilities of the control and instrumentation system are an integrated function of the engineering and diagnostic workstations.

The engineering workstations shall be configured as per Figure 12Figure 12.



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Keyboard Mouse


Engineering display

units

Figure 12: Engineer Workstation Configuration

The engineering and diagnostic workstations include functionality and tools for the following as a minimum:

• control and instrumentation system diagnostics for all equipment in the Contractor’s scope of supply including but not limited to diagnostic alarms on the following:

• DCS components

• Field components will be handled by FieldCare (not part of ControCad)

• Network and network components

• Power supplies

• Third Party interfaces provided by the Contractor to all Third Party systems including those provided by Other Project Contractors, provided that the 3rd party diagnostic alarms have been engineered and made available

• Time Synchronisation system

• control and instrumentation system configuration

• document management

• asset management

• functional software and hardware engineering

• field component configuration and connection



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• cabling and termination engineering

• closed loop diagnostics

• alarm diagnostics

• HMI graphics building

• report building

• database management

• system administration

• Boiler Protection

• Visual displays of plant simulations (forced inputs and outputs)

• Ability to configure and modify the Turbine Control System

All data for each applicable control and instrumentation system area’s hardware and software configuration shall be arranged in its own common engineering database such that any configuration change need only be made once and shall subsequently be propagated to and reflected in all the applicable documentation. The overall configuration shall utilise physical segregated data storage for each of the Plant Areas (Power Islands and Balance of Plant).

A comprehensive back-up and disaster recovery system shall be provided for all software programs, configuration and parameter data of all Plant Areas. The engineering and diagnostic workstation shall include hardware for backup and archiving of data, the management of its retrieval and automatic revision control for changes tracking.

The engineering and diagnostic workstation application programs shall have a graphical representation and utilise object-oriented programming. Facilities for database queries from third party systems shall be provided.

Drawings on the engineering and diagnostic workstation shall reflect their latest change or modification. The functional control diagram shall be configured such that they reflect every destination of signals having multiple destinations. All documentation shall be produced using the forward documentation process to ensure an accurate reflection of the system configuration and status at all times. A forward documentation system shall be provided which produces the as built drawing immediately upon changes being been made and accepted. (On request printouts shalll be provided).

All changes and modifications to control and instrumentation system software shall be made using the engineering and diagnostic workstation. Testing of the changes shall be initiated manually before it is permitted to transfer anything to the control and instrumentation system modules via the process communication bus system. These changes shall be possible at any time without disturbing the control and status of the plant on load. All tuning constants shall be parameterised and can be altered on line without disturbances to the control and instrumentation system.

Full security of data, safety and integrity of all control functions and data shall be guaranteed. The system shall be fully protected from the possibility of data corruption, external changes and computer viruses and software corruption. Data in the engineering and diagnostic workstation shall be password protected. A minimum of six levels of security access shall be provided.



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3.2.3.5.7.2 DOCUMENTATION MANAGEMENT SYSTEM

The Engineering and Diagnostic workstation shall provide a complete Documentation Management System (DMS), which shall cater for all type of documents, produced by the engineering and diagnostic workstation. Any change in one document shall automatically propagate to all related and linked documentation. All field loop and control and instrumentation system diagrams, with details of devices, tag numbers, KKS codes, terminations, junction boxes and racks etc. shall be managed within 2 automatically synchronised databases, one being SmartPlant Instrumentation tool (for the field), and the other one CONTROCAD (for the control system). Field loops and interface circuits shall include the full loop, showing the complete functionality of the loop, even where the devices in part of the loop are not part of the Works.

The documents produced and maintained through the DMS shall form an integral part of the engineering and diagnostic system. No ambiguity or inconsistency shall exist between the programs / software loaded on the control and instrumentation system and the DMS documents.

The system shall be comprehensive in its management and control of the documents of each of the Plant Area. This shall include controlling the differing stages of modifications that each plant sub-system may find itself in.

Automatic prevention of duplication of numbering or ambiguity shall be built into the system. The system shall contain master templates for each type of document produced or maintained.

3.2.3.5.8 EQUIPMENT ROOMS

The Employer shall provide Control Rooms, Equipment Rooms and Battery Rooms as indicated in Appendix 13 – Control, Battery and Equipment Rooms. The Contractor shall complete the all columns in Appendix 13 – Control, Battery and Equipment Rooms as per Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

The Contractor’s and the Engineer’s final requirements and layouts for the various equipment rooms shall be clarified and if need be, modified during the system engineering phase.

The Contractor shall install all control and instrumentation automation equipment in a cubicle in an equipment room.

All cubicles forming part of the Works shall be similar in size and appearance and shall conform to the following:

• floor mounted with suitable dust and vermin proofing

• bottom cabling access

• earthing

• front and rear access

• temperature monitoring per cubicle

• Powder coated RAL 7035

The Contractor shall make provision for designs, equipment and furniture as specified in the LOSS Diagrams and below for the various equipment locations:



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3.2.3.5.8.1 POWER ISLAND EQUIPMENT ROOMS

The Power Island equipment rooms, station equipment rooms and Balance of Plant equipment rooms (including sub-stations) shall be designed for installation of the control and instrumentation, electronic and rack mounted cubicles.

Cubicles provided by Other Project Contractors such as the electronic cubicles for the turbine control / protection, generator protection, AVR, synchronisation system, generator fault recorders, expert system computers and other equipment as defined and identified by the Engineer during system engineering shall also be included in the equipment room layout design.

The 24 V batteries shall be installed by the Contractor in separate battery rooms.

The 24 V battery charger systems shall be installed by the Contractor in separate battery charger rooms

The 220 V batteries shall be installed by the Contractor in separate battery rooms.

The 220 V battery charger and UPS systems shall be installed by the Contractor in separate battery charger rooms

The Contractor’s design shall cover the following as a minimum:

• Power requirements

• Power distribution


• Any special electromagnetic interference isolation.

• EMC isolation against all Radio / cellular telephone interference

• Cable routing

• Electrical plug points

The Contractor shall provide all cable secondary racking, cable trays, and conduits required for the installation of his equipment.

The Contractor shall provide one engineering workstation as per Section 3.2.2.2 and Figure 12Figure 12 in each of the six Power Island equipment rooms.

3.2.3.5.8.2 BALANCE OF PLANT EQUIPMENT ROOMS (INCLUDING SUB-STATIONS)

The Contractor’s control and instrumentation equipment for the various Balance of Plant areas shall be located in the closest existing sub-station equipment room which has space available. The locations of the sub-stations are as shown in the layout drawings in Appendix 12 – Project Drawings.

The Contractor shall provide all cable secondary racking, cable trays, and conduit required for the installation of his equipment.

The Contractor shall provide one engineering workstation as per Section 3.2.2.2 and Figure 12Figure 12 in the SSB equipment room and one in the WTP equipment room.



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3.2.3.5.9 PLANT INFORMATION SYSTEM

The Contractor shall provide, as part of the Works, a Plant Information System (PIS) that is a central database repository for the long term storage of all plant information produced at Medupi Power Station. This shall include plant information generated by the Contractor’s control and instrumentation systems, Others Project Contractor’s (such as the Turbine Control & Protection system, Generator Condition Monitor, Boiler Plant Health and Condition Monitoring calculator, H2 plant, N2 plant and Laboratory etc.), as well as other sources identified by the Engineer. The final list of systems that will be incorporated in the PIS shall be clarified and finalised during the system engineering phase. The PIS shall include all modules for the analysis of all the plant information including alarm data, SOE and all control and instrumentation system calculated variables.

The Contractor shall engineer and configure on the PIS clients as part of the works all process graphics and trends available on the Operator Workstations.

The system shall be used for the remote access and retrieval of near real-time and historical plant information by the PIS Clients (as defined in section 3.2.2.2). The station PIS shall provide easily accessible information for power plant technical services such as operating, maintenance, and engineering.

The Contractor shall provide the Works for the PIS and historian in accordance with the technical guideline, EED_GTD_C&I_004 in Appendix 14 – Project Standards.

Appendix T contains typical information for the PIS. Specific documentation and data shall be submitted by the Contractor for approval to the Engineer during System Engineering.

3.2.3.5.9.1 PLANT INFORMATION STORAGE

The PIS shall store the plant information for all Power Islands and the Balance of Plant on fully redundant physically separated servers. The redundant PIS data server shall be physically separated from the control and instrumentation system servers, engineering and diagnostic workstations and operator workstations and shall be provided by the Contractor as part of the Works. A one-million tag PIS licence shall be provided by the Contractor.

The PIS shall be able to store all analogue tags with a precision adjustable from 0,1% to 10,0% in the Historian. The average precision for all analogue tags together shall be 1,0%. All events shall be recorded upon state changes with a timestamp resolution and accuracy of 1 ms or better. The PIS data servers shall store a minimum of 5 years of all historical plant information on-line at maximum resolution for access by the PIS clients. The PIS shall store all analogue, digital, calculated and control variables.

The PIS shall be able to backup the historical plant information stored on the PIS data servers to external hot-swappable HDDs, while on-line and without any loss of availability and functionality of the PIS. External hot-swappable HDD’s shall be supplied by the Contractor for 3 years of off-line data, as part of the Works. The PIS shall not lose any data even under the most extreme situation such as a multiple unit trip.



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3.2.3.5.9.2 PIS CLIENT INTERFACE

The Contractor shall supply, as an integral part of the Works, web server software that allows the PIS clients, with the appropriate user rights and a standard Internet Browser, to view all the real-time and historical plant information from the PIS in the form of:

• trends,

• chronological lists,

• reports,

• process graphics,

The design and engineering of web pages that supply the real-time and historical plant information from the PIS to the PIS clients shall be provided. A maximum of 150 PIS clients shall be able to access all real-time and historical plant information from the PIS simultaneously.

3.2.3.5.9.3 STATION BUSINESS LAN INTERFACE

The Plant Information System shall connect to the station business LAN through a redundant firewall. The firewalls will be provided by the Employer.

The Contractor shall install and supply all cabling required connecting to the station business LAN and all necessary associated equipment such as connection boxes and switches. All bus cable jointing, splicing and termination forms part of the Works.

The Contractor shall assess the cable routes at site and provides full details for the Engineer’s approval.

3.2.3.5.9.4 REDUNDANCY

The PIS data servers shall be fully redundant. In the event of a failure of one of the PIS data servers, the redundant PIS data server shall automatically take over its functions, without any loss in availability or functionality of the PIS. When the failed server is returned to service it shall automatically update and realign itself with the master server. The PIS servers shall synchronise all data continuously to ensure no data loss or corruption of data in case of a server failure.

All interfaces to the PIS shall be fully redundant. There shall be no single point of failure. The failure of any single component (for example, a switch, a NIC, a cable, or a firewall) shall not result in any loss of functionality or availability of the PIS. The PIS network architecture shall be designed such that the redundant PIS data servers can be physically separated and located at any two nodes on the network.

3.2.3.5.9.5 TIME SYNCHRONISATION

The PIS data servers shall be synchronized with the GPS system supplied as part of the Works.

3.2.3.5.9.6 SECURITY

A user shall be requested to enter a username and password, before being able to access the configuration and diagnostic software of any PIS component.



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3.2.3.5.9.7 PIS DATABASE STRUCTURE

The databases on the PIS data servers shall hold all plant data and shall be open to the queries from the control and instrumentation system data servers and the PIS client. The database structure shall be modifiable to fit the needs of Medupi Power Station.

Any changes made to the database shall be made real-time and on-line, and all changes shall be effective without restarting any part of the system.

The PIS shall make real-time and historical plant information available to third party applications through OPC communication. All the PIS databases shall be accessible by third party software applications on the PIS clients by means of SQL queries. These third party software applications shall be able to read data from all the PIS databases.

3.2.3.5.9.8 REPORTS

As a minimum the following reports shall be created and generated by the Plant Information system on a regular basis:

• Alarm log

• Hourly log

• Daily log

• Shift log

• Operating log

• Incident review logs

• Running time and status change log

• Calculated points

• Summary logs

• C&I Fault log

• Statistical evaluation reports

• Special Dust and Pollutant Emission reports

• Water Mass Balance Report

• CPP, Regeneration and Demineralisation Reports

• Metering reports as specified in the technical guideline, EED_GTD_C&I_003 in Appendix 14 – Project Standards.

• Appendix 14 – Project Standards

All reports generated by the Plant Information System shall be viewable on all PIS Clients. The final list of reports generated by the PIS shall be clarified during the system engineering phase.

The PIS shall automatically create and transmit the generator energy data report over FTP to the Employer’s Phoenix Server as defined in the technical guideline, EED_GTD_C&I_003 in Appendix 14 – Project Standards.



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3.2.3.5.10 OTHER SYSTEMS AND INTERFACES REQUIREMENTS

3.2.3.5.10.1 FIREWALLS BETWEEN CONTROL AND INSTRUMENTATION

SYSTEM AND ESKOM BUSINESS LAN

The Control and instrumentation system’s bus network shall be secure and only functions directly related to the operation, maintenance and engineering of the plant shall be directly accessible from the Control and instrumentation system via the password protected functions. The Control and instrumentation system shall be protected from any unauthorized input by either human or system. The integrity of the Control and instrumentation system shall be ensured at all times. Intruder access attempts shall be alarmed immediately after the attempt.

Where information exchange is required with the Employer’s business information network or LAN, the Contractor shall provide the applicable hardware and related services to set-up, configure and test the firewall and data. The security requirements of the firewall, related ports and applicable protocols e.g. OPC (OLE for process control) will be configured and tested as per the Employer’s security standards as provided in Appendix 14 – Project Standards. . The final firewall design will be coordinated with the Employer’s information technology group.

The Contractor shall be responsible to set-up and configure the plant information system and database of the control and instrumentation system to ensure that plant data can be securely integrated with the Employer’s application software and tools. The Contractor shall be required to demonstrate the bi-directional capability of the data interface to assure the Engineer’s agent that the system is secure.

3.2.3.5.10.2 SOOTBLOWERS

The Contractor shall interface and integrate the Steam Sootblowers and Water Cannons as per the Specification Documentation:




In addition the Contractor shall interface, provide and install the rack and power supply for the rack mounted computer of the Furnace Cleaning Expert System provided by Other Project Contractors.

3.2.3.5.10.3 RADIO TELEMETRY SYSTEM

The Contractor shall provide a Radio Telemetry system as part of the Works. Where the radio telemetry system is the only communication method the radio telemetry shall only be used for information and set points, not for direct control or protection signals. Radio telemetry can be used as a second and different communication method for redundancy. The Contractor shall provide the radio telementry equipment as per the following:






PAGE 88 OF 135133

The radio equipment shall be housed in wall mounted cabinets suitable for the environmental conditions.

Appendix E contains typical datasheets for the Radio Telemetry System. Specific design details shall be submitted by the Contractor for approval to the Engineer during System Engineering.

3.2.3.5.10.4 COMPRESSOR CONTROL AND INSTRUMENTATION SYSTEM

The Contractor shall provide control and automation equipment for all compressors and interface the control equipment to the control and instrumentation system. The Contractor shall implement the operating and control philosophy of the Other Project Contractor supplying the compressor plant. The Contractor shall provide the compressor control equipment as per the following:




3.2.3.5.10.5 PULSE JET FABRIC FILTER PLANT (PJFFP) SYSTEM

The Contractor shall provide the control and management system integrated with the control and instrumentation system in accordance with the following documents:




The Contractor shall provide for two separate Automation Units (UFG27A and UFG27B) in the PJFFP substation located in close proximity of the PJFFP.

3.2.3.5.10.6 ROTARY AIR PRE-HEATERS

The Contractor shall provide the interface to the control and fire detection system of the rotary air pre-heaters in accordance with the following documents:




The Contractor shall provide a cubicle in each of the Power Island control and instrumentation equipment rooms for housing the air heater control and fire detection system provide by an Other Project Contractor.

3.2.3.5.10.7 GENERATOR PROTECTION, AVR & SYNCHRONISER SYSTEM

The Generator Protection and Synchroniser interface shall form part of the Works. The Contractor shall provide a hardwired interface in accordance with the following documents:





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3.2.3.5.10.8 GENERATOR CORE HEALTH MONITORING SYSTEM

The Generator Core Health Monitoring interface is part of the Works. The Contractor shall provide an interface in accordance with the following documents:





3.2.3.5.10.9 BOILER TUBE WALL TEMPERATURE MONITORING SYSTEM

The Contractor shall implement the evaluation criteria for the boiler thick wall temperature monitor provided by Other Project Contractors in the control and instrumentation system. The Contractor shall provide the works in accordance with the following documents:



3.2.3.5.10.10 GENERATOR FAULT RECORDER

The Generator fault recorder interface is part of the Works. The Contractor shall provide an interface in accordance with the following documents:





3.2.3.5.10.11 H2 PLANT

The Contractor shall integrate the control, operation and monitoring of the H2 plant into the control and instrumentation system as part of the Works. The Contractor shall implement the operating and control philosophy of the Other Project Contractor supplying the H2 plant. The Contractor shall provide H2 plant control and instrumentation system in accordance with the following documents:





3.2.3.5.10.12 N2 PLANT

The Contractor shall integrate the control, operation and monitoring of the N2 plant into the control and instrumentation system as part of the Works. The Contractor shall implement the operating and control philosophy of the Other Project Contractor supplying the N2 plant. The Contractor shall provide N2 plant control and instrumentation system in accordance with the following documents:



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3.2.3.5.10.13 FIRE DETECTION AND ALARM ANNUNCIATION SYSTEM (FDAS)

The Contractor shall provide fire protection range pressure transmitters to alarm the activation of the fire protection system (water spraying) to the Power Island and Balance of Plant operators. The Contractor shall further alarm gradual pressure decays.

The Contractor shall provide the interface to the fire detection system provided by Other Project Contractors.

The Contractor shall implement an interlock, on all conveyer belts where fire protection activation pressure transmitters are installed, to stop the relevant belt where the fire protection system is activated.

The Contract shall provide the pressure transmitters and interface in accordance with:





3.2.3.5.10.14 CONVEYOR LONG LINE PROTECTION SYSTEM

The Conveyor Long Line Protection system will be provided by the Employer for all the Coal and Ash conveyors. The Contractor shall provide the interface to the Conveyor Long Line Protection system in accordance with the following documents:







The Contractor’s interface to the Conveyor Long Line Protection system shall provide for all information to be interfaced to the control and instrumentation system. This includes the unique identification codes (KKS) of each device such that the nature, origin and position of any activated switch will be indicated in the HMI

3.2.3.5.10.15 ASH AND COAL STACKER AND RECLAIMER

The ash and coal stacker and reclaimer machines and the instrumentation on the machines up to a junction box will, be provided by the Employer. The Contractor shall provide the local control and automation equipment including the local HMI panel. The local control and automation equipment shall have a redundant hot swappable processor



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unit and a fibre optic interface for transmitting the data from the machine to the control and instrumentation system. The Contractor shall implement the operating and control philosophy of the Other Project Contractor supplying the stacker and reclaimer machines.

The Ash and Coal Stackers and Reclaimers shall be remotely and locally controlled. The local HMI for these machines shall be located in cabins onboard the machines. The detailed design of the HMI shall be finalised during system engineering.

Two independent and concurrent operations with associated input devices shall be possible. Failure of one operator processor shall limit the loss to one operator input and two operator display units.

The Contractor shall supply the ash and coal stacker and reclaimer control and instrumentation equipment in accordance to the following documents:





3.2.3.5.10.16 AUTOMATIC VOLTAGE REGULATOR (AVR)

The AVR interface is part of the Works. The Contractor shall provide a hardwired interface in accordance with the following documents:




3.2.3.5.10.17 BOILER TUBE LEAK DETECTION

The Contractor shall integrate the tube leak detection instrumentation into the control and instrumentation system to form a tube leak detection system. The Contractor shall provide the tube leak detection system as part of the Works in accordance with the following documents:




3.2.3.5.10.18 HV YARD ERTU

The Contractor shall provide a bus interface for the HV yard interface. The type of bus interface shall be determined during Systems Engineering, possibilities include (IEC60870-5-101) The Contractor shall provide the system in accordance to the following documentation:







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3.2.3.5.10.19 AGC

The Contractor shall provide the AGC functionality based on an IEC60870-5-101 bus protocol directly connected to the Employer’s BME.

The physical interface between the control and instrumentation system and the BME panels shall be a fibre optic cable that meets the requirements of the fibre optic converters at both ends of the cable. It shall be operated at a preferred speed of 4 800 bit/s, 9 600 bit/s or 19 200 bit/s at full duplex in both command and monitor direction at the same speed. The preferred speed shall be 9 600 bit/s.

The frame format FT 1.2, single character 1 and the fixed time out interval shall be used exclusively in this companion standard link layer.

The link transmission procedure – address field of the link shall be unbalanced transmission with one byte, two bytes, structured or unstructured.

The frame length shall be a maximum of 255 bytes.

Mode 1 (Least significant byte first), as defined in clause 4.10 of IEC 60870-5-4, shall be used exclusively in this companion standard application layer

The following standard ASDUs shall be used:

Table 8: Standard ASDU used in IEC60870-5-101 implementation

<1> := Single-point information M_SP_NA_1

<2> := Single-point information with time tag M_SP_TA_1

<3> := Double-point information M_DP_NA_1

<4> := Double-point information with time tag M_DP_TA_1

<5> := Step position information M_ST_NA_1

<6> := Step position information with time tag M_ST_TA_1

<7> := Bitstring of 32 bit M_BO_NA_1

<9> := Measured value, normalized value M_ME_NA_1

<10> := Measured value, normalized value with time tag M_ME_TA_1

<11> := Measured value, scaled value M_ME_NB_1

<15> := Integrated totals M_IT_NA_1

<16> := Integrated totals with time tag M_IT_TA_1

<45> := Single command C_SC_NA_1

<46> := Double command C_DC_NA_1

<47> := Regulating step command C_RC_NA_1



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<48> := Set point command, normalized value C_SE_NA_1

<49> := Set point command, scaled value C_SE_NB_1

<51> := Bitstring of 32 bit C_BO_NA_1

<70> := End of initialization M_EI_NA_1

<100> := Interrogation command C_IC_NA_1

<101> := Counter interrogation command C_CI_NA_1

<103> := Clock synchronization command C_CS_NA_1

The following performance requirements shall be met for AGC:

• AGC Controls for up to 16 generators shall be accepted and processed by the control and instrumentation system such that a setpoint change on the Power Island control system is completed within 4 seconds from time of control despatch from NCC.

• Analogue value changes from the Power Island shall be reported at least every 2 seconds to NCC, given that the NCC poll rate per communication circuit is 1 second.

The AGC functionality shall be implemented in function group EFG02, from where the unitised AGC instructions shall be dispatched to each Power Island.

The AGC functionality using the IEC60870-5-101 bus protocol shall undergo a separate factory acceptance testing in the Contractors factory and witnessed by the Engineer.

3.2.3.5.10.20 ENERGY METERING AND DATA ACQUISITION (EMDAS)

The Contractor shall provide an Energy Metering and Data Acquisition System and interface to the control and instrumentation system and PIS. The EMDAS system forms an integral part of the automation system and shall be engineered into the control and instrumentation system. The technical guideline, EED_GTD_C&I_003 in Appendix 14 – Project Standards shall serve as information and a guide to the Contractor. The Contractor shall propose an Integrated Energy metering System that shall fulfil the functional requirements of EED_GTD_C&I_003 in Appendix 14 – Project Standards and in accordance with the following documentation:




The Contractor shall supply hardware that can measure input pulses of 50ms or less for the measurement of the meter output pulses.

Appendix O contains typical information about the EMDAS. Specific design details shall be submitted by the Contractor for approval to the Engineer during System Engineering.

MAIN TURBINE (MT) CONTROL & PROTECTION



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The MT control and protection shall be provided by the Employer. The Contractor shall provide an interface to the MT Control & Protection system as part of the Works. The operation and monitoring of the MT shall be integrated in the Power Island HMI. All time-stamping information as generated by the MT Control & Protection system shall be captured by the control and instrumentation system.





3.2.3.5.10.21 VIBRATION & CONDITION MONITORING AND ANALYSIS SYSTEM FOR MT, DRAUGHT GROUPS & TURBINE AUXILIARIES

The Contractor shall provide all software and all hardware for a vibration condition analysis system for the main turbine, draught groups and feedpumps as part of the Works, as defined in the following documents:




For the draught groups, feed pumps and mills, the Contractor shall supply all needed hardware and software to acquire the signals from the field vibration sensors (provided by others), evaluate these signals, gather and evaluate associated equipment process conditions (temperatures, pressures, flows, etc.) and generate equipment health monitoring results based on this information.

For the main turbine, the Contractor shall supply all needed hardware and software to acquire turbine vibration monitoring signals from the turbine OEM’s vibration signal acquisition system and utilize these signals as well as other process conditions (load, temperatures, pressures, flows, etc.) to generate equipment health monitoring results.

The Contractor’s process experts and the Contractor’s condition monitoring system experts will collaborate as needed with the equipment OEMs to determine the process variables to be measured (in addition to vibration/position data) that create the best correlation to equipment health and accurate condition monitoring.

Appendix P contains typical architectural drawings for the Vibration Condition Monitoring System. Specific design details shall be submitted by the Contractor for approval to the Engineer during System Engineering.

3.2.3.5.10.22 EXPERT SYSTEMS

The Contractor shall provide the following in the rooms as defined in Table 9Table 9 as part of the Works:

• 19” rack mounted computers (PC) and servers,

• space for 19” rack mounted computers and servers supplied by the Engineer,

• 19” rack cubicles

• UPS power supply to the cubicles to cater for all computers to be installed in the 19” rack cubicles ,



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The Contractor shall provide the computers (PC) and Servers (with RAID5 3HDD) to the equivalent available specification at procurement meeting the minimum requirements as follows:

3.2.3.5.10.22.1 SPECIFICATION FOR 19” RACK MOUNTED COMPUTER (PC)

• Multi-core/ dual Processor

• 2 Redundant Power Supplies (550W each)

• 4GB RAM (4x1GB) (4 x DIMM Sockets)

• 1TB S-ATA hard drive

• On board GB LAN Port

• 5x USB 2.0 ports, serial port, parallel port and PS/2 ports

• On board Video & Audio

• Multi-write DVD drive

• Microsoft XP Professional or latest tested and proofed Microsoft equivalent for the application.

3.2.3.5.10.22.2 SPECIFICATION FOR 19” RACK MOUNTED SERVER (WITH RAID5 3HDD)

• Multi-core/ Quad Processor

• 2 Redundant Power Supplies (550W each)

• 8GB RAM (4x2GB) (4 x DIMM Sockets)

• 3 x 1TB S-ATA hard drives (Hot swap compatible, RAID5 setup)

• Dual on board GB LAN Ports

• 4x USB 2.0 ports, serial port, parallel port and PS/2 ports

• On board Video

• Microsoft XP Server or latest tested and proofed Microsoft equivalent for the application.

The Contractor shall provide the Works as per the following documents:





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Table 9: Expert System Computers and Cubicles

Hardware and

Operating SystemApplication Software

Conveyor Condition Monitoring System LOSS_CONDITION_MONITORING 1 PC CSSBA Contractor Other Project Contractor C&I Equipment Room SSB

Conveyor Condition Monitoring System LOSS_CONDITION_MONITORING 1 PC CSSBA Contractor Other Project Contractor C&I Equipment Room SSBConveyor Condition Monitoring System LOSS_CONDITION_MONITORING 1 PC CSSBA Contractor Other Project Contractor C&I Equipment Room SSB

Steam Sootblower Expert System LOSS_BLR_SBWB 1 PC CU1A Other Project Contractor Other Project Contractor C&I Equipment Room Unit 1

Water Cannon Sootblower Expert System LOSS_BLR_SBWB 1 PC CU1A Other Project Contractor Other Project Contractor C&I Equipment Room Unit 1

Tube Leak Detection System LOSS_BLR_TLD1 1 PC CU1A Contractor Other Project Contractor C&I Equipment Room Unit 1

Plant Health System 1 PC CU1A Other Project Contractor

Other Project Contractor

(signal evaluation

parameters only) C&I Equipment Room Unit 1

Boiler LifeTime Monitoring System (Thick

Walled Components) LOSS_BLR_SUP2 1

SERVER

(RAID5 3HD) CU1B Contractor


(TUV Certified Software) C&I Equipment Room Unit 1

Electrical Engineering Server LV 1

SERVER

(RAID5 3HD) CU1C Other Project Contractor Other Project Contractor C&I Equipment Room Unit 1

Electrical Engineering Station LV 1 PC CU1C Other Project Contractor Other Project Contractor C&I Equipment Room Unit 1

Electrical Engineering Server MV 1

SERVER

(RAID5 3HD) CU1C Other Project Contractor Other Project Contractor C&I Equipment Room Unit 1Electrical Engineering Station MV 1 PC CU1C Other Project Contractor Other Project Contractor C&I Equipment Room Unit 1






(signal evaluation




SERVER




Electrical Engineering Server 1

SERVER


Electrical Engineering Station 1 PC CU2C Other Project Contractor Other Project Contractor C&I Equipment Room Unit 2


SERVER

(RAID5 3HD) CU2C Other Project Contractor Other Project Contractor C&I Equipment Room Unit 2Electrical Engineering Station 1 PC CU2C Other Project Contractor Other Project Contractor C&I Equipment Room Unit 2






(signal evaluation




SERVER





SERVER




SERVER







(signal evaluation




SERVER





SERVER




SERVER







(signal evaluation




SERVER





SERVER




SERVER







(signal evaluation




SERVER





SERVER




SERVER


Continuous Emission Monitoring System LOSS_BLR_EM 1 PC CSCA Other Project Contractor Other Project Contractor C&I Station Computer Room



Continuous Emission Monitoring System LOSS_BLR_EM 1 PC CSCB Other Project Contractor Other Project Contractor C&I Station Computer Room

Continuous Emission Monitoring System LOSS_BLR_EM 1 PC CSCB Other Project Contractor Other Project Contractor C&I Station Computer RoomContinuous Emission Monitoring System LOSS_BLR_EM 1 PC CSCB Other Project Contractor Other Project Contractor C&I Station Computer Room


SERVER

(RAID5 3HD) CSCC Other Project Contractor Other Project Contractor C&I Station Computer Room

Electrical Engineering Station 1 PC CSCC Other Project Contractor Other Project Contractor C&I Station Computer Room


SERVER

(RAID5 3HD) CSCC Other Project Contractor Other Project Contractor C&I Station Computer RoomElectrical Engineering Station 1 PC CSCC Other Project Contractor Other Project Contractor C&I Station Computer Room

To be Supplied by:Cubicle

Name Expert System LOSS

Number of

PC/Server

PC/Server

Specification

3

3

Housed in Room

Numer of

Cubicles

per room

1

3

3

3

3

3



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3.2.3.5.11 FIELD EQUIPMENT

3.2.3.5.11.1 GENERAL

The field equipment requirements are detailed in the following Specification documents:





• Appendix 12 – Project Drawings

Field equipment availability shall match that of the control and instrumentation system, so that it does not constitute a weak link. All field equipment operates shall over an ambient

temperature range of -10°C to 70°C.

All field equipment shall comply with the hazardous zone classification as per SANS10108 listed in Appendix 14 – Project StandardsAppendix 14 – Project Standards.

Field equipment and equipment installations shall comply with the FIIS standards as given is Appendix 14 – Project StandardsAppendix 14 – Project Standards. Subcontractors shall follow the OEM Contractor’s Quality Standard.

All field equipment and their electrical connections shall be rated IP 66 or better, or are housed in water and dust proof cases rated IP 66 or better. Additional protection hoods and enclosures must protect those transmitters situated outdoors or in adverse environments. All submerged equipment shall be rated IP 68.

The Contractor shall implement one pilot installation for each unique field equipment type in the Contractor’s Yard for approval by the Engineer before any further installation of such field equipment. The pilot installation shall be used as the quality reference for all further installations

Appendix Q contains typical hookup drawings and data for field equipment. Specific hookup drawings and data shall be submitted by the Contractor for approval to the Engineer during System Engineering.

All instrument labels shall be stainless steel.

For all Contractor supplied piping, tubing, fittings, valves and manifolds, material mill test reports shall be provided to the Engineer for approval as per GGS1427 (3.2 BS EN 10204 (2004)). This material shall not be shipped to the project site until these quality assurance documents are approved by the Engineer.

3.2.3.5.11.2 LIMITS OF SUPPLY AND SERVICES (LOSS)

The LOSS diagrams shall demarcate the responsibilities for the various stages of the project from system engineering up to and including commissioning. The Contractor shall supply, install and commission all field equipment as identified in the LOSS diagrams.



PAGE 98 OF 135133

3.2.3.5.11.3 INPUT/OUTPUT FUNCTION BLOCK DIAGRAMS (IO BLOCKS)

The Input / Output Function Block Diagram (IO Blocks) shall indicate the binary and analogue inputs and outputs to and from the control and instrumentation system for the applicable device.

Each IO Block shall also indicate which control and instrumentation system inputs / outputs are hardwired signals and which are bus signals.

3.2.3.5.11.4 TRANSMITTERS

3.2.3.5.11.4.1 GENERAL

The Contractor shall ensure that the transmitters supplied as part of the Works are compatible with the relevant primary measurement element, and that the transmitters are suitable and adequate to fulfil the function and accuracy requirements.

All transmitters provided by the Contractor as part of the Works shall be HART devices and satisfy the Asset Management requirements of the Works. Any supply of devices without HART protocol shall be for the approval of the Engineer.

All analogue transmitters (excluding temperature transmitters) shall be provided as standard with built in local indicators. Transmitters with high turn down ratios, while still conforming to the accuracy / repeatability specification shall be provided. Calibration of all transmitters shall be the responsibility of the Contractor.

All pressure and differential pressure transmitters shall as a minimum comply with the following:

• IP 66 rated

• 0.075% accuracy of span

The transmitters supplied by the Contractor shall conform to the requirements specified in the sections below and Appendix 14 – Project Standards.

3.2.3.5.11.4.2 TAPPING POINTS AND ISOLATION VALVES

Each transmitter shall have a separate tapping point, impulse line and manifold.

3.2.3.5.11.4.3 IMPULSE PIPING

The Contractor shall provide all certified impulse piping in accordance with GGS1427 (3.2 BS EN 10204 (2004)) and welding according to GGS 1407 in Appendix 14 – Project Standards.

The Contractor shall allow, for each field installation LOSS diagram that requires impulse piping’ the following impulse piping lengths:

Impulse piping – 15 meters per installation

The Contractor shall install all impulse piping in accordance with the specification in Appendix 14 – Project Standards.

Each transmitter measuring any medium other than fluids or steam shall have a connection fitted to blow through the impulse line from the tapping point to the transmitter,



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at the transmitter manifold. The blowthrough connection shall be provided with a tight sealing quick coupling connection.

Quality assurance documentation for all Non-Destructive Testing conducted shall be submitted to the Engineer for approval. Non-destructive Testing shall be in accordance with EST0002, EST0009 and GGG 1323.

All pipe work supplied by the Contractor shall be inclusive of supports, valves, fittings, condensing chambers for closed vessel level transmitters, transition pieces to primary isolating valves and drains to provide complete impulse, equalising and blow-down lines for all instruments.

All pipe work designs shall be submitted to the Engineer for approval prior to installation. The Contractor shall do one pilot installation of at least six impulse pipes for approval by the Engineer before any further installation of impulse piping. The pilot installation shall be used as the quality reference for all further installations

3.2.3.5.11.4.4 MANIFOLDS

The Contractor shall provide all manifolds in accordance with the technical specifications in Appendix 14 – Project Standards.

3.2.3.5.11.4.5 TEMPERATURE TRANSMITTERS

The Contractor shall provide all temperature transmitters in accordance with the technical specifications in Appendix 14 – Project Standards. The Contractor shall cater for 30 centimeter length of thermocouple for each LOSS where he provides the thermocouple. Exact length of thermocouple elements shall be finalised during System Engineering.

3.2.3.5.11.4.6 MAGNETIC FLOW METERS

As a minimum, the Contractor shall supply magnetic flow meters with the following parameters/features:

• Engineering units ( Metric Units)

• 220 V power supply

• integrators

• ranges starting at zero with no cut-offs

The output signal of all magnetic flow meters is a 4 to 20 mA signal. Magnetic flow meters in the valve pits shall be IP 68 rated, all the rest at least IP66.

3.2.3.5.11.5 TRANSMITTER RACKS, EQUIPMENT CABINETS & FIELD PANELS

The Contractor shall supply, erect and commission all transmitter racks, equipment cabinets and field panels required for the Works to the specification of the transmitter installation specifications of Appendix 14 – Project Standards.

All transmitters provided as part of the Works are mounted in suitable transmitter racks, equipment cabinets or field panels.

Where transmitters cannot be mounted in transmitter racks, equipment cabinets or field panels the Contractor shall obtain approval from the Engineer. Such transducers shall



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then be firmly mounted on stands or brackets as close as possible to tapping point, but taking due care in the location of the transmitters for the following:

• Allowance for safe and easy access for maintenance and calibration

• Allowance for the environmental conditions

• Allowance for the removal of equipment for maintenance in the vicinity of the transducer.

• Allowance for the environmental conditions in the vicinity of the transducer such as temperature and vibration damping.

The racks, equipment cabinets and field panels shall be supplied complete with all necessary holding down bolts and equipment to make a complete assembly.

The Contractor shall submit the final number, location, design, equipment content and layout of the transmitter racks, field panels and equipment cabinets to the Engineer for approval.

Appendix Q contains typical racks and stands for transmitters. Specific racks and stands shall be submitted by the Contractor for approval to the Engineer during System Engineering.

3.2.3.5.11.6 SWITCHES

Flow, temperature and pressure switches shall not be permitted unless a statutory requirement and approved by the Engineer.

Mechanical limit switches shall not be permitted unless a statutory requirement and approved by the Engineer or for the use in electrical actuators. If used, switches shall be 3-wire change over contact type switches to facilitate contact monitoring.

Contacts making action shall be instantaneous by a snap action. There shall be no interconnecting of contacts. All contacts shall be capable of handling at least 120 mA at 36 V continuously.

All contacts shall be protected against adverse environmental effects e.g. dust, moisture, corrosive gasses, high temperature etc…

3.2.3.5.11.7 ANALYSERS

The Contractor shall provide interfacing to analysers as per:






3.2.3.5.11.8 JUNCTION BOXES

The Contractor shall provide junction boxes meeting the requirements of Appendix 14 – Project Standards.



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During detailed design the Contractor shall optimise junction box size and quantity subject to approval of the Engineer.

3.2.3.5.11.9 LOCAL CONTROL PANELS (LCP)

The Contractor shall provide LCP as part of the Works as per Appendix 9 – Limits of Supply and Services and to the specification of Appendix 14 – Project Standards.

Each LCP shall be assigned to plant and equipment as specified in Appendix 4 – Instrument Schedule and in Appendix 2 – Drive & Actuator Schedule.

The plant and equipment allocated to each LCP shall be clarified during the system engineering phase.

LCPs are remote operator stations located in the field. The LCP’s interface to the control and instrumentation system through the redundant process communication bus

3.2.3.5.11.10 LOCAL CONTROL STATIONS (LCS)

The Contractor shall provide LCS as part of the Works as per Appendix 9 – Limits of Supply and Services and to the specification of Appendix 14 – Project Standards.

The philosophy of operation for the LCS shall be as per the technical guideline EED_GTD_C&I_007 in Appendix 14 – Project Standards.

3.2.3.5.11.11 VALVES

The Contractor shall provide valves meeting the requirements of the Works and process plant Original Equipment Manufacturer as detailed in:


• Appendix 9 – Limits of Supply and Services,

• and the datasheet reference in the Schedules.

Valves shall further comply with the following standards Appendix 14 – Project Standards or equivalents specified by the process plant Original Equipment Manufacturers in:

• ASME B16.34 and ASME B16.34a

• ESKSCAAB8

The contractor shall provide one spare set of valve inserts for each valve forming part of the Works for one Power Island. Power Island 6 valve inserts shall be used for acid cleaning and blow through for the entire plant.

Appendix Q contains datasheets for typical concept design valves. Project specific valves shall be finalised by the Contractor with the assistance of Other Project Contractors during System Engineering.

3.2.3.5.11.12 ACTUATORS

The Contractor shall provide actuators meeting the requirements of the process plant Original Equipment Manufacturers detailed in:

• Appendix 2 – Drive & Actuator Schedule,




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All actuators forming part of the Works shall be electric actuators complete with HARTING plugs. Any deviation from this shall be motivated to the Engineer for approval.

All actuators shall be supplied from the same manufacturer and the same range from the manufacturer where possible.

Electrical actuators shall comply with the actuator standards in Appendix 14 – Project Standards.

The Contractor shall be responsible for the correct sizing, adaptability and suitability of all actuators provided as part of the Works. This includes verification of all information regarding actuators from the mechanical process plant Original Equipment Manufacturers.

The Contractor shall provide all necessary flanges and linkages, from the actuator to the damper shaft or valve spindle. Dimensions of the shafts and technical details such as turning direction, multi-turn, quarter turn, standard linear turn (not modified multi-turn) are determined during the system engineering phase.

Direct mounted flanged type actuators are preferred for binary dampers with a keyed adaptive coupling (damper shaft / actuator shaft). The Contractor shall mount and secures the actuator on a mounting or plinth which is included as part of the Works.

The design and sizing of actuators shall take into account the duty cycle for the plant operation. Actuators shall be designed and selected such that no overheating occurs under worst-case conditions. The environmental conditions shall be taken into account. In particular, the de-rating for the altitude at Medupi Power Station shall be taken into account in the design.

All special tools (other than the normal hand tools) shall be provided by the Contractor at Completion.

Appendix Q contains typical datasheets and information for actuators. Project specific actuators shall be finalised by the Contractor with the assistance of Other Project Contractors during System Engineering.

3.2.3.5.11.12.1 PNEUMATIC & HYDRAULIC ACTUATORS

The connections between the pneumatic actuators, air supplies and petitioners shall be implemented with flexible tubes. The fittings installed on the actuators shall not change the control characteristics of the pneumatic valves.

The positioners provided by the Contractor as part of the Works shall provide an appropriate analogue output signal with a local display of the positioned output, input or valve position.

Continuous 4 - 20 mA control signals shall be used to interface with hydraulic controllers as well as with subordinate position controllers.

The designs of the hydraulic converters shall be such that on loss of the signal from the control and instrumentation system, the control element freezes in its current position. In certain safety related applications the control element, in the case of failure of the control signal, fails open or closed depending on the process conditions.



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3.2.3.5.11.12.2 ELECTRIC ACTUATORS CONTROL BEHAVIOUR

The controllers shall be forced to manual, for the following conditions:

• Failure of the actuator power supply

• Operation of the thermal overload relay of the electric actuators

• Excessive actuator winding temperatures

• Failure of associated measurements used for control of the actuator

• Failure of the position feedback of the actuator if used for control of the actuator

• Excessive deviation of the final control element from its set point

• Operation of the torque limit switch

• Touching of the hand wheel

3.2.3.5.12 CABLING

3.2.3.5.12.1 CABLING SCOPE DEFINITIONS

The scope of field / instrument cabling is defined as being all cabling between the field equipment and first junction / splitter box.

The scope of bus cabling is defined as being all cabling forming part of the process communication bus system and bus interfaces to third party systems.

The scope of trunk cabling is defined as being all cabling between the junction boxes or groupings of field / instrument cables and the control and instrumentation system, and between the switchgear and the control and instrumentation system.

The scope of power supply cabling is defined as being all cabling required to power field equipment.

The scope of secondary racking is defined as all racking / conduit / trunking etc. including the racking supports from the field measurement / drive to the junction / splitter box.

The scope of primary racking is defined as all main racking including racking supports for multiple cables from the splitter / junction box to the control and instrumentation system as well as between control and instrumentation systems.

3.2.3.5.12.2 CABLING SCOPE AND REQUIREMENTS

The Contractor shall provide for the design, supply, installation, termination, labelling, testing, documentation and commissioning of:

• all bus / communication cabling (fibre optic and co-axial cabling)

• field / instrument cabling

• switchgear control cabling

• temperature compensating cabling from thermocouples to mV / mA converter transmitter

• power supply and distribution cabling



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• power cable from splitter box to drive / actuator

• power cable to 220 V AC instrumentation

• instrument trunk cabling

• field and bus cabling interfacing to equipment supplied by Other Project Contractors

• Junction, splitter boxes and marshalling cabinet as per the field installation standards of Appendix 14 – Project StandardsAppendix 14 – Project Standards.

In accordance with Appendix 9 – Limits of Supply and Services and to the specification of Appendix 14 – Project Standards

The Contractor shall provide the design, supply and installation of:

• Secondary racking, conduits and trunking from field devices to junction boxes, other termination points or connections to primary racking

• Interfaces to the primary racking supplied by Other Project Contractors

in accordance with Appendix 9 – Limits of Supply and Services and to the specification of Appendix 14 – Project Standards

The Contractor shall standardise on the type and core number of all cables used. Al field / instrument cabling shall have a minimum of 2 pairs (UVG2ACM) and all trunk cables from junction boxes shall have 16 pairs (UVG16ACM) as required by the junction box standard in Appendix 14 – Project Standards and drawing 0.00/2713 rev 6. in Appendix 12.

All cables forming part of the Works shall at a minimum insulated with flame-retardant reduced halogen emission PVC outer sheath (emit a mass of not more than 15% halogen).

The Contractor shall provide management, design expertise and systems for all cables, cabling and secondary rack routing forming part of the Works. The Contractor shall be the overall technical leader, and takes final responsibility for all cabling and associated work that forms part of the Works.

The routes for field cabling, power supply cabling and the secondary racking is of a consistent and integrated design, that shall take into account different cabling and racking routes for common modes of failure, multiple Power Island tripping and the redundancy concepts of the control and instrumentation system design.

The Contractor shall design all trunk cabling and provide the designs to Other Project Contractor for routing of the cabling on primary racking. The primary cable rack routing design, supply and installation of the primary racking throughout the plant will be done by Other Project Contractors and will be clarified during the Clarification period before design freeze. The Contractor shall interface with the supplier of the primary racking for purposes of an integrated and optimal cable routing design.

The Contractor shall use the same cable design system as the Employer’s cable design system used for the primary racking, routing and cable design. The Contractor shall interface the cable design and routing database with the primary racking and routing database of the Other Project Contractor. This is in order to ensure an integrated and optimal cable routing and cabling design for the complete power plant. The system and interface requirements shall be clarified during Systems Engineering.



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The Contractor shall supply as final information the cabling, cable and termination database in a software compatible system as will be specified by the Engineer during Systems Engineering.

The Contractor provides the cabling in accordance with the following technical guidelines and specifications provided in Appendix 14 – Project Standards:

• 0.00/1310

• 0.66/55053

• GGS 0183

• ISO 898-1 and 898-5

• NWS 1525 and 1527

• SANS 10142-1, 1411 (parts 1-7) and 1574

• SANS 60794-1-1

• IEC 61238-1

• GGS 0386 with the following errata included:

• Table 6 – Column heading “Number of Conductors” to read “Number of pairs of Conductors”

• Table 6 – to include for UVG16ACMV

All installed cables are tested and Certificates of Compliance shall be issued prior to commissioning of any plant as per the SANS 10142-1 specification.

All cables provided as part of the Works must be secured with suitable cable glands, straps or clamps on racks, in cubicles, switchgear rooms, control rooms, equipment rooms etc.

The Contractor shall submit the final design and routing documentation of all cabling forming part of the Works to the Engineer before installation or procurement.

Appendix Q contains typical datasheets and information for cabling. Project specific datasheets and information for cabling shall be submitted by the Contractor for approval to the Engineer during System Engineering.

3.2.3.5.12.3 CABLE SCHEDULES

Accurate records shall be kept in Cable Schedules by the Contractor for all cabling forming part of the Works.

The Contractor shall provide the cable schedules inclusive of origin, target, type, size and termination details. The Contractor shall provide the termination schedules for all cables forming part of the Works.

3.2.3.5.12.4 CABLE MANAGEMENT SYSTEM

The Contractor shall provide as part of the Works, a cable management system to optimise the utilisation of cables forming part of the Works.

A cable stock schedule shall be maintained by the Contractor to record all cables delivered to Medupi site and removed from Medupi site. The cabling installed shall be reconciled with the cable stock schedule.



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All installed trunk cables shall be subject to measurement, for purpose of payment, after installation.

The Contractor shall allow for each field installation LOSS diagram the following:

• Field cables – 25 meters per installation

• Secondary racking from junction box to field equipment – 25 meters per installation

• Secondary racking from junction box to primary racking – 25 meters per installation

The cable management system shall be capable of exporting all cable data in Microsoft Excel format

3.2.3.5.13 EARTHING, LIGHTNING AND ELECTRICAL PROTECTION

All testing and verification of the earthing (grounding) system for the control and instrumentation system as well as earthing for power supply and distribution shall form part of the Works.

The Contractor shall be responsible for implementing the correct earthing concept for reliable and safe operation of the control and instrumentation system.

All metal instrument casings shall be properly earthed (grounded) to the earth mat to avoid any electromagnetic interference, which may arise from portable FM transmitters, cell phones and other equipment used on the plant. Any other means of earthing to eliminate any interference shall be the Contractor's responsibility.

All field cables as well as data link cables shall be earthed (grounded). The cables shall be earthed at one end or both ends depending on the interference signal and shall comply with an overall earthing arrangement.

The Contractor shall design and supply all necessary lightning and surge protection equipment required to protect all open air C&I circuits and equipment.

Particular consideration shall be given for earthing and lightning protection on all Balance of Plant equipment, outside the boiler / turbine area, such as the conveyors, stackers and reclaimers etc.

All earthing shall be in accordance with the following standards and specifications:

• 0.54/393 in Appendix 14 – Project Standards

• SANS 10142-Part 1

• SANS 61312-Parts 1-4

• NRS 042

3.2.3.5.14 POWER SUPPLIES

3.2.3.5.14.1 GENERAL

The Contractor shall provide as part of the Works, all necessary UPS (220 V AC) and battery chargers (24 Volt DC) including the power distribution as required for the control and instrumentation system and field devices.

The Employer shall provide space for the battery charger/ UPS and batteries in:



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• Six unitised battery and charger rooms in the Auxiliary Bay as per drawing 0.84/501

• Two station battery and charger rooms in the Auxiliary Bay as per drawing 0.84/501

• One Balance of Plant battery room and equipment room for housing the chargers in the SSB building as per drawing 0.84/908

• One WTP battery room and equipment room for housing the chargers in the WTP building as per drawing 0.84/641

• Space for integrated battery and charger UPS in each of the Balance of Plant substations as per drawing 0.84/567 and 0.84/532, 0.84/562-566, 0.84/592-605, 0.84/794, 0.84/978, 0.84/979.

All drawings as provided in Appendix 12 – Project Drawings.

All plant shall be capable of safe shutdown without damage in the event of partial or total loss of electrical power, and be designed to accept a sudden restoration of electric power, without damage, and without operator intervention.

All permanent or temporary installations shall be subjected to the statutory requirements as explained in OHS Act 85 of 1993 and SANS 10142-1 for the wiring of premises which include the issuing of a certificate of compliance (CoC) before an installation can be commissioned or approved by the Engineer.

The Employer shall provide 400 V AC bulk supplies to all the charger rooms and electrical sub-stations.

The Contractor shall provide for the design, manufacture, factory testing, delivery to site, off loading, connection, installation, site testing, commissioning and hand-over of all the 24V DC and 220 V AC power supply systems required for the control and instrumentation system, HMI system, field devices and computer systems supplied as part of the works.

Appendix R contains typical datasheets and conceptual single line diagrams for power supply components. Project specific datasheets and single line drawings for power supply components shall be submitted by the Contractor for approval to the Engineer during System Engineering.

3.2.3.5.14.2 QUALITY OF SUPPLY

The Contractor shall assume a maximum quality of supply from the Employer’s 400 V AC to be as follows:

3.2.3.5.14.2.1 TYPICAL QUALITY OF SUPPLY

3.2.3.5.14.2.1.1 Normal AC supply conditions

Extremes of these parameters can occur simultaneously:

• Voltage: ± 5 percent

• Frequency: ± 2.5 percent

• Voltage unbalance: Negative Phase Sequence (NPS) voltage up to 0.02 of nominal Positive Phase Sequence (PPS) voltage

• The Zero Phase Sequence Voltage component can be up to 1% of the PPS component.



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• The harmonic distortion of the supply voltage under normal operation will be as follows:

• The Total Harmonic Distortion (THD) of the voltage can be up to 5% of the fundamental component.

• The voltage waveform can contain harmonic components up to the 100th harmonic.

• The amplitude of any individual component can be up to 1% of the fundamental component.

Where variable speed drives are provided the harmonic current values as prescribed in this paragraph shall be adhered to. For all operating conditions, individual harmonic currents shall not exceed (these are measured at the electrical supply boards):

• rms amplitude of 100/n percent, where n is the harmonic number.

• sub-harmonic currents shall not exceed the RMS amplitude of 100n percent, where n is the fraction given by the sub-harmonic frequency divided by the fundamental frequency.

3.2.3.5.14.2.1.2 Abnormal AC power supply conditions

The supply voltage frequency can reach limits of up to 52.5 Hz and fall as low as 47.5 Hz. This condition can last for up to 1 minute.

The amplitude and duration of temporary abnormal voltage conditions which can occur on the power supply will be as follows:

• Short duration abnormal conditions: Short duration under voltage conditions arise either due to a loss of supply or the supply voltage being depressed due to a short circuit on the network.

• Loss of power supply: When the supply is disconnected, the supply voltage either drops rapidly to 0% of nominal value or is sustained at low amplitude at a reduced frequency because of back generation of electrical drives. The initial voltage amplitude during these conditions is less than 80% of nominal value and decays with a time constant of up to 1.5 seconds. The time duration from loss of supply until supply restoration is between 1 second and 2.5 seconds.

• Short circuits: Depression of supply voltage due to short circuits can result in voltages as low as 0% of nominal value. The duration of the drop can be up to 1 second.

• Over voltages: Over voltages with amplitudes of 110% of nominal value can occur for up to 10 seconds.

• Medium duration power supply deviations: Voltage depressions of medium duration can be caused by the switching of load, such as starting induction motors. The supply voltage can fall as low as 75% of nominal value and the duration of this depression can be up to 15 seconds.

• Power swings: An alternative source of this abnormal condition is when power swings occur after a severe disturbance on the network. The supply voltage amplitude will oscillate at a frequency between 0.2 and 2 Hz. In this case, the voltage can fall as low as 65% of nominal and can rise up to 110% of nominal during a swing. The voltage will not fall below 70% for longer than 0.5 seconds. However, these oscillations, or repeated abnormal voltage conditions, can continue for up to 60 seconds.



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• Long duration power supply deviations: Long duration abnormal supply voltage conditions usually originate from operating the plant at its limits. The supply voltage can be up to 110% of nominal value and can drop as low as 90% of nominal value. The duration of such abnormal conditions is up to 6 hours.

• The following lightning and switching surge conditions can occur on the power supply system:

• Lightning impulse: Phase-to-earth and/or phase-to-phase lightning impulses with a front time of 1.2 µs, a time-to-half-value of 50 µs, a peak value up to that indicated in the Switchgear Parameter Table and with both positive and negative polarities, as described in IEC 60060-1.

• Switching impulse: Phase-to-earth and/or phase-to-phase switching impulses with a front time of 250 µs, a time-to-half-value of 2500 µs, a peak value up to that indicated in the table in paragraph 5.1 and with both positive and negative polarities, as described in IEC 60060-1.

3.2.3.5.14.2.2 POWER CONDITIONING

Where power conditioning equipment (e.g. batteries and chargers, inverters, rectifiers, etc.) shall be required to improve or alter the availability, security, voltage, frequency or any other characteristic of the available power supplies as indicated in Section 3.2.3.5.14.2.1 in order for the Contractor’s Works to perform according to its specification, the Contractor shall supply such equipment.

Power conditioning equipment shall be designed for reliability and ease of maintenance, and shall incorporate adequate redundancy to allow for fault repairs and routine maintenance without reducing the plant availability. Power conditioning equipment shall operate from the available power sources.

3.2.3.5.14.2.3 NON-LINEAR LOADS

Where non-linear loads such as variable speed drives are provided the following harmonic current limits, as measured at the supply point, shall apply:

• For all operating conditions, individual harmonic currents shall not exceed RMS amplitudes of 100/n percent, where n is the harmonic number with the power frequency (50 Hz) being the fundamental.

• Sub-harmonic currents shall not exceed the RMS amplitudes of 100n percent, where n is the fraction given by sub-harmonic frequency divided by fundamental frequency.

3.2.3.5.14.3 POWER DISTRIBUTION CONCEPT

The Contractor shall follow the following concept when doing the detail design of the power supply and distribution.

3.2.3.5.14.3.1 220 V AC UPS AND 24 V DC UNITISED POWER SYSTEMS (POWER ISLAND 1 TO 6 16 METER LEVEL AUXILIARY BAY)

• Power Supply for all unitised control and field equipment forming part of the Works.

• Power Supply for all unitised control and field equipment for the turbine and generator control, supervisory, and protection systems supplied by the Employer.

• Power supply for the unitised engineering and diagnostic system for the turbine and generator control, supervisory, and protection systems supplied by the Employer.



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• Power Supply for the 19” rack cubicles housing computers for expert systems as given in Section 3.2.3.5.10.22.

• Power Supply of all unitised computer based equipment forming part of the Works

• Power Supply for the unitised engineering and diagnostic system forming part of the Works

• Power Supply to the unitised operator workstations in the PICS

3.2.3.5.14.3.2 STATION 220 V AC UPS AND 24 V DC POWER SYSTEMS AT POWER ISLAND 6 16M LEVEL AUXILIARY BAY

• Power Supply for station common control and field equipment in the Power Island including but not limited to GPS and Station Electrical Distribution forming part of the Works

• Power Supply for station common control and field equipment in the power island supplied by the Employer

• Power Supply for the simulator in the temporary and permanent simulator suites.

• Power Supply for the EDCR4-6

• Power Supply for equipment in the PICS common to Power Islands 4-6

• Power Supply for the EOD operator station in the PICS

• Power Supply for Simulator HMI and Simulator server equipment (temporary and permanent)

• Power Supply for one half of the redundant hardware for the station common computer equipment such as the PIS, Historian etc.


Power supply for the common equipment in the power island can be from either Station Power Supply Rooms. The Contractor shall optimise the power distribution for availability and cable lengths.

3.2.3.5.14.3.3 STATION 220 V AC UPS AND 24 V DC POWER SYSTEMS AT POWER ISLAND 3 16M LEVEL AUXILIARY BAY

• Power Supply for station common control and field equipment in the power island including but not limited to GPS and Station Electrical Distribution forming part of the Works

• Power Supply for station common control and field equipment in the power island supplied by the Employer

• Power Supply for the EDCR1-3

• Power Supply for equipment in the PICS common to Power Island 1-3

• Power Supply for one half of the redundant hardware for the station common computer equipment such as the PIS, Historian etc.




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Power supply for the common equipment in the power island can be from either Station Power Supply Rooms. The Contractor shall optimise the power distribution for availability and cable lengths.

3.2.3.5.14.3.4 WTP 220 V AC UPS AND 24 V DC POWER SYSTEMS AT WTP BUILDING

• Power Supply for WTP control and field equipment

• Power Supply for the WTPRCP for the WTP


• Power Supply of all WTP computer based equipment forming part of the Works

3.2.3.5.14.3.5 SSB 220 V AC UPS AND 24 V DC POWER SYSTEMS AT SSB BUILDING

• Power Supply for SSB control and field equipment

• Power Supply for the Balance of Plant in the SSB


• Power Supply of all SSB computer based equipment forming part of the Works

3.2.3.5.14.3.6 SUB-STATION 220 V AC UPS AND 24 V DC POWER SYSTEMS AT BALANCE OF PLANT

• Power Supply for Balance of Plant control and field equipment in vicinity of sub-station. The Contractor shall optimise the power distribution for availability and cable lengths between sub-stations.

All power supply systems for the Power Islands, Station, WTP and SSB shall consist of separate redundant 24V battery banks and separate redundant 220V battery banks in the allocated battery rooms and chargers / supplies in the allocated charger / equipment rooms. Each of the battery banks of the redundant set shall have a minimum capacity of 4 hours at maximum load. Each power supply system shall consist of redundant charger/supplies with each charger / supply rated at the maximum possible load. The power supply system shall be configured such that either of the battery banks can be charges from either charger and supply via either supply.

All power supply systems for the Balance of Plant shall consist of redundant integrated charger / supply / batteries rated for a minimum capacity of 4 hours at maximum load per redundant system. Each of the redundant integrated battery/charger supplies shall be housed in separate cubicles in the sub-station.

The Contractor shall provide the batteries, battery chargers and UPS as per the following specifications in Appendix 14 – Project Standards:

• GGG 0838

• GGP 0848

• GGP 0849

• GGS 0836

• GGSS 0456



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• GGSS 0769

• GGSS 0829

• GGSS 0839

• GGSS 0840

• GGSS 0846

• GGSS 1000

• SANS 1632 (parts 1,2 & 3)

• SANS 1652

• IEC 61238-1

• GGPP 0823

• GGP 0843

• GGS 0837

• GGSS 0842

3.2.3.5.14.4 AC AND DC ISOLATION FACILITIES

Isolation facilities are applicable to power circuits, where the term power circuits are defined in the Employer’s Plant Safety Regulations GGR 0992 and ESKPVAEY6 in Appendix 14 – Project Standards.

Isolation facilities are provided for each individual field device. Each isolation facility is lockable and shall be approved by the Engineer before installation.

Both sides (positive and negative) of DC supplies shall be circuit breaker / fuse protected. On AC supplies, all phases shall be circuit breaker / fuse protected. Neutral shall have a link in place of a fuse. Where isolators are used, a positive means of position indication shall be supplied (visible air gap, or mechanical indication, which is an integral part of the moving mechanism). Locking facilities shall be provided to prevent tampering when isolated. These locking facilities shall also be suitable to accommodate padlocks with a 40 mm base and long hardened shackles.

The power sub-distribution shall use mini circuit breakers (MCBs) with integral overload protection, which discriminate electrical faults, to restrict them to the smallest possible branch or system. Grading of the circuit breakers shall be designed to locate / isolate a fault to the smallest possible area.

The equipment shall be rated for the total load and fault currents, to prevent overheating during short circuits, before the power supply is successfully isolated.



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3.2.3.6 SIMULATOR

The Contractor shall provide a stand-alone full scope, high fidelity engineering and training simulator as part of the Works. The simulator shall be based on Medupi Power Island 6. The simulator shall be designed such that it complies with the performance criteria and the acceptance tests in Appendix 15 of the Specification. The simulator design shall allow for expansion and / or modifications in the future.

The methodology required for the execution of the Works for the simulator shall be detailed in Section 3.2.3.4.12 of this Specification.

The Contractor shall provide the Works in accordance with the applicable portions of following standard:

American National Standard for Fossil Simulators – Functional Requirements, ISA-77.20-1993 (R2005)

Appendix A contains typical simulator conceptual documentation. Project specific documentation shall be provided by the Contractor, for approval by the Engineer, during System Engineering.

3.2.3.6.1 SIMULATOR USE

The Contractor shall provide the Simulator with the capability such that the Employer can perform the following:

• Training of operating staff in safe and efficient operation of the plant.

• Training of engineering and maintenance staff in the detailed process response and control of the plant.

• Evaluation of control, process and equipment dynamic changes.

• Verification of operating procedures.

• Performing of control logic checking of the design control software before FAT.

• Performing of engineering analysis tests prior to implementation of modifications on both the process and the control logic of the implemented control and instrumentation system.

The simulator’s modelling fidelity and capabilities shall be such that it can be used as described above.

The Contractor shall provide a simulator capable of simulating the following as a minimum:

• Complete plant start-ups (cold, hot, warm)

• Plant shutdowns

• Load changes

• Normal operating conditions

• Abnormal operating conditions

• Emergency operating conditions



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• Practising of Initial Conditions

3.2.3.6.2 SIMULATOR SYSTEM PERFORMANCE

All components of the Simulator shall be supported and maintainable until the end of life of the plant as defined in Section 3.2.3.5.1.1.

The availability of the Simulator shall be 99 % or greater measured annually. For any sub-systems or components of the Simulator, which when faulted affect the functioning of the Simulator, the Mean Time to Repair (MTTR) shall be less than 8 hours.

No single system failure mode shall repeat itself more than once every three months. No redundancy is required on the sub-systems or components of the Simulator, unless lack of redundancy will violate the reliability and availability requirements specified above.

The simulator performance shall be demonstrated to ensure that it is accurate and meets the requirements of Appendix 15.

3.2.3.6.3 SIMULATOR SCOPE

The simulator modelling scope shall include all plant areas which are not controlled by the Contractor’s control and instrumentation system but which are operated from the Contractor’s HMI (e.g. the turbine protection and control and instrumentation systems). This is applicable for the total power island.

All plant models shall be designed based on first principles to simulate plant operation from cold start-up to maximum load under steady-state and transient conditions, taking into account the effects of changing parameters such as pressure, temperature, flow, and level, and also the effects of these parameters due to starting and stopping of all plant auxiliary equipment. All models shall provide response of the same magnitude and direction as the plant would give under and equivalent set of circumstances.

The control and instrumentation system models shall be a complete duplication of the systems simulated including all controllers, mode selection, interlock and alarm functions. Control and instrumentation system models for motors, solenoid valves and similar devices simulated shall include all permissive, alarm outputs, interlocking and tripping functions.

The Contractor shall provide the Simulators with the capability such that the Employer can perform the following:

• Training of operating staff in the safe and efficient operation of the plant.

• Training of engineering and maintenance staff in the detailed process response and control of the plant.

• Evaluation of control, process and equipment dynamic changes.

• Verification of operating procedures.

• Performing of control logic checking of the design control software before FAT.

• Performing of engineering analysis tests prior to implementation of modifications on both the process and the control logic of the implemented control and instrumentation system.



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3.2.3.6.4 TEMPORARY SIMULATOR SUITE (SS-TEMP) AND PERMANENT

SIMULATOR SUITE (SS-PERM)

The Employer will provide a temporary simulator suite located at Power Island 6 auxiliary bay 16m level for housing the simulator until the permanent simulator suite at Power Island 4, Auxiliary Bay 16m level is ready for occupation. The Contractor shall move the simulator equipment to the Permanent Simulator Suite and restore the Temporary Simulator Suite to its condition prior to establishment of the Temporary Simulator Suite. Refer to control and instrumentation rooms provided in the auxiliary bay as per Appendix 12 – Project Drawings.

The Contractor’s design of the temporary and permanent simulator suites shall include, as a minimum, the following:

• Lighting and luminaries requirements (normal and emergency)

• UPS power requirements and supply

• Electrical plug points UPS and non-UPS

• Channelling for cabling


• Provision of Telephones at each desk area

• Air conditioning heating and cooling loads

• Any special isolation from electromagnetic interference.

• Space for office PC equipment for trainer.

• One-way viewing from instructor of all trainee actions

• Interior space allocation and architectural details

• Provision of LAN connections at each desk area

• Sound suppression

The final requirements and layout of the desks, furniture and hardware shall be discussed and clarified during the Simulator system engineering phase (technical clarification meetings). The design for the Temporary and Permanent Simulator Suites shall be provided to the Engineer for approval. The Contractor shall provide furniture for the temporary and permanent simulator suites in accordance with the general requirement for the PICS.

3.2.3.6.5 SIMULATOR HARDWARE

The Contractor shall provide one simulator operator workstation. The Simulator operator workstations’ hardware shall be a replica of the Power Island 6 operator workstation hardware (with the same number and type of the hardwired trip push buttons, operating display units and pointing devices). The Contractor shall provide an Instructor Station as part of the Works. The Instructor station shall be equipped with a minimum of two 21 inch LCD flat screen display units which shall allow the training instructor to monitor and control any training scenario or function. The instructor station shall allow the instructor to view any HMI screen that the trainee on the simulator operator desk can view or operate.

The Contractor shall provide complete engineering facilities for the simulator. The simulator engineering facilities shall allow the Employer to perform maintenance and / or



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development on all the simulator sub-systems and programs. The simulator engineering facilities shall be separate from the instructor station hardware.

The Contractor shall provide a method of creating and restoring back-ups of the entire simulator database (plant models, control and instrumentation system models, trainee history, etc).

3.2.3.6.6 SIMULATOR SOFTWARE AND FUNCTIONALITY

The Contractor shall provide an integrated industry standard development software package. The front end of the development software package for plant models and control and instrumentation system models shall employ object-orientated functionality making it user friendly to operational and maintenance engineers in the long term, without the need for manual intervention and/or specialist simulator engineering skills.

The Simulator operator workstation HMI graphics shall be identical in all respects to Power Island 6 operator workstation’s HMI graphics.

The simulator software shall be designed such that the simulator response is the same as the response of the reference plant. The control response shall be realistic and controls delays are not noticeable and do not, in any way, detract from the training value of the simulator.

The Contractor shall emulate the control algorithms and control logic of all plant areas in the simulator scope. This includes control algorithms and logic developed by Other Project Contractors (e.g. the turbine control and protection system etc.). The emulation shall be complete and designed so that no difference can be discerned between the operation of the simulator and the reference plant. Changes and upgrades made to the ALSPA control and instrumentation and HMI systems can be readily implemented on the simulator, by the instructor, through an electronic translator, with no programming required.

The instructor station shall, as a minimum, be capable of the following functions as a minimum:

• Simulation software initialization

• Set initial process conditions

• Freeze / Run

• Developing of Initial Conditions (IC’s)

• Backtrack / Replay at normal speed

• Selectable snapshot and initialization

• Setting remote plant functions

• Setting external parameters

• Multiple malfunction injection

• Slow, real and fast time simulation

• Fast Forward / Rewind functions (Faster than Real time) (Fast times like Fast Evacuation of the condensate, Fast Turbine Heat-up/cooldown are implemented in the simulator executive. The Fast Forward/Fast Rewind function shall be provided via the Scenario Analyzer tool).



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• Event logging of all simulation events including trainee and instruction actions

• Trainee performance evaluation system

• Selecting snapshots and saving

• Selectable communication (intercom) with adjustable volume from the instructor room to the simulator room

• Permanent sound with adjustable volume from the simulator room to the instructor

• Full digital video and two channel audio recording of all training sessions

• Full process operator action recording in all training sessions

• Background sound replicating the Plant performance sounds

The simulator shall provide the instructor with a facility for simulator training administration by means of login identification codes and password to identify a minimum of 150 trainees at any given time.

3.2.3.6.6.1 PLANT MALFUNCTIONS

The Contractor shall provide a minimum of 60 variable malfunctions. The list of variable malfunctions will be clarified and finalised during the Simulator system engineering phase. In addition to the variable malfunctions, the Contractor shall provide the instructor, through the malfunction feature the ability to fail every pump, fan, motor, control valve, binary valve, heat exchanger, transmitter and control element on the simulator. The Contractor shall provide the simulator with capability to add or modify malfunctions.

3.2.3.6.6.2 EXTERNAL PARAMETERS

The Contractor shall provide as part of the Works a minimum of 10 external parameters such as ambient temperature, coal quality, ambient pressure, cooling water temperature, grid frequency etc. The list of external parameters included in the simulator will be clarified and finalised during the Simulator system engineering phase.

3.2.3.6.7 SIMULATOR DOCUMENTATION

The Contractor shall submit documentation for the simulator as specified in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) . The documentation provided by the Contractor for the simulator shall be comprehensive and includes all information necessary for the Employer to use, maintain and modify the simulator.

3.2.3.6.7.1 INSTRUCTOR / MAINTENANCE DOCUMENTATION

The instructor documentation shall provide the simulator instructors with sufficiently detailed information to start up, shut down, and operate the simulator during a training session, as well as detailed instructions for the use all simulator hardware.

The documentation shall provide descriptions of the physical makeup and components in the system, functional operation of the system, and a listing of system parameters such operating / design temperatures.

The instructor documentation shall include the following as a minimum:

• Simulator Operation Manual

• Simulator Maintenance Manual



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• Simulator Engineering Manual

• Simulator Instructor Quick Reference Manual

3.2.3.6.7.2 SOFTWARE DOCUMENTATION

The Contractor shall provide detailed and complete software documentation for all programs which are used to produce the simulator. The documentation shall be organized and prepared to enable the Employer to understand all the programs to sufficient depth to be able to modify these programs, to support changes in the simulator models, and to be able to evaluate control and process dynamics.

3.2.3.6.7.3 HARDWARE DOCUMENTATION

The simulator hardware documentation shall provide sufficiently detailed information to maintain, modify and troubleshoot the simulator’s hardware.

3.2.3.6.8 SIMULATOR PERSONNEL TRAINING

The Contractor shall conduct training sessions for instructors who will operate the simulator and Engineers who will modify and maintain the simulator as per Section 3.2.3.10.4.

3.2.3.7 PLANT CODIFICATION AND LABELLING

Codification and labelling of all equipment and documentation supplied as part of the Works shall be the responsibility of the Contractor.

Plant codification is done according to the following standards in Appendix 14 – Project Standards:

• NMP 45-7

• N.PSZ 45-45

• ALPHA KKS 01

• ALPHA KKS 02 (Rev 1)

Plant labelling shall be in accordance with the codification specifications in Appendix 14 – Project Standards. English descriptions shall be provided for all labelling and shall be done in accordance with the policy GGPP1511 in Appendix 14 – Project Standards.

The Contractor shall use the Employer-specific interpretations of the KKS standards, which will be advised after the Commencement Date by the Engineer. The KKS Plant codes generated by the Contractor shall be submitted to the Engineer for approval. The Contractor shall code all Plant within his scope of Works according to the KKS classification system to breakdown level 3. The relevant KKS codes thus allocated shall appear on all Plant-related documentation, drawings, lists and correspondence.

Abbreviations to descriptions on the labels are generally not acceptable. Where abbreviations are unavoidable, due to the limited number of characters that can be engraved/etched on labels, the abbreviations shall be in accordance with the Employer’s abbreviation standard ALPHA KKS 01, in Appendix 14 – Project Standards.



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KKS codes down to third level for equipment are used on documentation (e.g. drawings, manuals, equipment lists, cable schedules etc) as a unique identification means.

The KKS plant codes generated by the Contractor shall be submitted to the Engineer for approval.

The Contractor shall be responsible for ensuring the accuracy, completeness and consistency of the designations in all documents. This applies both to designations within documents (Plant designations) and of documents (document designations). The Contractor shall submit these for the Engineer’s approval. The Contractor shall provide the Engineer with the following:

• Outline drawings or diagrams showing the Contractor's reference coding for systems and equipment;

• In respect of items procured by the Contractor from another manufacturer or vendor, the Contractor shall provide the name of the actual manufacturer and his coded drawing or reference numbers and relevant technical data for identification purposes.

3.2.3.8 DOCUMENTATION AND SOFTWARE CONTROL

3.2.3.8.1 GENERAL

The documentation requirements cover the various stages of the project, from the engineering stages through installation and commissioning and most importantly for the operating, maintenance and training stage of the project.

As a minimum, the Contractor shall provide as part of the Works, the documentation specified in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) specifies the following:

• The limits of supply of the documentation, i.e. whether the documentation is provided / maintained by the Contractor or Engineer

• The type of documentation provided

• The software format (where applicable) in which the documentation is provided

• The stage in the project execution during which the documentation is provided as a deliverable (either by the Contractor or Engineer)

The following standards as given in Appendix 14 – Project Standards are adhered to for all documents submitted by the Contractor:

• GGS 0182

• GGS 0315

• N.PSZ 45-698 (as far as reasonably possible)

• GGS 0445

• IEC 62079

• VGB R 171E



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• VGB R 170C

The Contractor shall be responsible for planning the supply of the documentation during the various project stages and to provide the documentation in accordance with Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

3.2.3.8.2 DOCUMENTATION SYNOPSIS

The documentation synopsis is a summary and general view of the entire documentation package which shall be provided by the Contractor. The documentation synopsis provides a clear indication of its content and consists of documentation that is specific to this project. The document synopsis includes the format and layout of each document in the documentation package.

Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) shall be incorporated and updated as necessary in the Contractor’s documentation synopsis and is submitted to the Engineer for approval. Appendix S contains examples of sample documentation. Documentation Synopsis requirements shall be reviewed and accepted by the Engineer within two months after Contract Award.

In addition to the typical documentation referenced in the table of documentation requirements, the Contractor shall include the standard documentation and procedures in the documentation package:

• Design standards, codes of practice, design guidelines, installation, commissioning and optimisation procedures

• Drawing system description and index

• Document management procedures

• Quality assurance documents

• Design modification procedure

• Data sheets of components, actuators, transmitters, control modules, printed circuit boards etc

3.2.3.8.3 OPERATING, MAINTENANCE AND TRAINING MANUALS

The Contractor shall provide operating, maintenance and training manuals that comply with the following requirements:

• IEC 62079 listed in Appendix 14 – Project Standards

• Medupi Maintenance URS as specified in Section 3 sub section 3.1

• Section 1.8.1.3.1 of this document

• VGB 171e listed in Appendix 14 – Project Standards

All manuals shall be provided in the English language.

The standard prescribes the type of information that is supplied by originators of user information, catalogues and schedules and other product support documentation required by the Engineer. It also prescribes the quality of documentation provided by the Contractor.



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The manuals shall be produced based on the agreed manual synopsis. The manual synopsis is a separate document from the documentation synopsis. The Contractor shall submit the manual synopsis to the Engineer for approval. Manuals for the control and monitoring of the plant using the HMI, which include navigation, alarm handling, normal and out-of-normal operations, plant start-up and shutdowns, shall be written by the Contractor. The Contractor shall provide the system manuals that describe the design, operating and maintenance philosophies of the control and instrumentation system, its subsystems and components as part of the Works.

3.2.3.8.4 MODIFICATIONS

The Contractor shall provide additional and amended pages, sufficient for all copies of manuals or documents sets to ensure that they are complete, inclusive of detail such as final settings and modifications. Such information shall be forwarded to the Engineer, within the period for reply, following receipt of agreement to equipment or system design modifications.

3.2.3.8.5 DOCUMENTATION CONTROL

The Contractor shall implement comprehensive document control of all documents. The document control and instrumentation system shall be implemented by the Contractor, as minimum contains the revision status of all documents in relation to the 'As Built' plant status.

Procedures, document control, flow diagrams and indexes are included in this system. The documentation register contains the following information and shall be submitted monthly, in a Microsoft Excel format, to the Engineer:

• Documentation number (Engineer and makers number)

• Revision

• Approval status

• Location of documentation at that stage

• Documentation description

All documentation submittals shall be effected via a documentation transmittal advice approved by the Engineer.

3.2.3.8.6 PROJECT COMPLETION DOCUMENTATION AND SOFTWARE

Software

At Completion of the last stage of the Works, the Contractor shall supply a copy of uncompressed data files reflecting all latest revisions of all documentation. Any program software licenses and agreements for software packages that are used for the Works form part of the Works and shall be handed to the Engineer.

The documents will be reviewed by the Engineer for correctness and conformance to the accepted design and agreed modifications.



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The Contractor shall provide all information developed for the Project in electronic native format as editable files and databases.

Where data is supplied in database format, the Contractor shall ensure that fully populated and verified databases (and their associated archives, where relevant) are handed to the Engineer for use in the SmartPlant Instrumentation (SPI) 2D Design Tool. The data provided by the contractor shall include as a minimum (but is not limited to):

• Loop diagrams

• Cable schedules

• Instrument Loop Lists

• Instrument Datasheets

• Product catalogue numbers

• Reference data pertaining to catalogue equipment

• Instrument serial numbers

• I/O Lists

• Trip Alarm Schedules

• Field Connection/Wiring Diagrams

The plant instrumentation data package (which constitutes the Instrument Schedule, Function IO Block Diagrams, Limits of Supply and Services, Cable Schedules) shall be appropriately configured and integrated in SmartPlant Instrumentation (SPI) so as to provide the Engineer with a fully populated, auditable instrumentation database, with all necessary integration links to facilitate data exchange, handling, and reporting.

The contractor shall ensure that necessary electronic native diagrams can be created in the required (Eskom) standard format for the following types of diagrams:

• Instrument Index

• Loop Drawings

• Termination Diagrams

• Wiring Diagrams

• Junction Box Layout

• Hook-up Diagrams

Configuration of the SPI database shall be such that the necessary MS Excel format list reports can be generated for the following:

• Instrument Index

• Instruments

• Instrument Schedule

• Instrument Loops

• Instrument Specifications

• Instrument Process Data

• Electrical Signal Lists



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• Cable Schedules

• Wiring Lists

In accordance with the Employer, the latest version of SmartPlant Instrumentation, Version 2007.4 (08.00.04.08), shall be used by the Contractor.

Acceptable database file formats shall include Microsoft Access, Oracle and SQL Server.

The Contractor shall have auditable quality control process and necessary verification procedures to ensure data integrity when transferring/loading data into SPI. The Contractor shall ensure that the delivered SPI data is free of any database exceptions and unassociated (“orphan”) entries.

Documentation

The Contractor shall on completion of the last Power Island update all preceding Power Islands with the Contractor’s latest system software versions including bug fixes or Service Packs of the system software.

The Contractor shall on completion of the last Power Island ensure that all Power Island application software is the same and that all modifications and bug fixes done throughout the project include for all of the Power Islands application software.

3.2.3.9 CONFIGURATION MANAGEMENT

The Contractor shall employ a comprehensive configuration management program in compliance with ISO 10007 to ensure that plant structures, components and computer software and firmware conform to approved design requirements.

In addition, the Works “As-Built” physical and functional characteristics shall be accurately reflected in documents and databases, including those for design, procurement, construction, operation, testing and training.

The configuration program shall be applicable for use throughout all phases of the project life cycle, including that of management of spare parts, replacement parts and product upgrades, and is part of deliverables at hand-over to the Engineer for use during the operation and maintenance phases of the plant.

Software and firmware

The Contractor shall mange the configuration of all software (application and system) and firmware throughout the project engineering phases until the Completion of the project. The management of the software and firmware shall include for both bug fixes and changes to the application software. The Contractor shall further manage the configuration of all changes made by the Contractor and the Engineer to the application software after Sectional Completion until the Completion of the project.

The configuration management system shall include a database for the management of all hardware, software (application and system) and firmware versions of all control and instrumentation equipment. The database shall further indicate who originated and approved the changes and include all motivation for all software changes.

The configuration further include the rollout of the updated application software for updating all other Power Islands control and instrumentation system software to reflect the latest changes at project Completion.



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3.2.3.10 TRAINING

3.2.3.10.1 GENERAL

The Contractor shall provide training on all equipment and systems included as part of the Works to the various categories of the Employer’s technical staff for the duration of the Works.

The objective of the training is to provide the Medupi Power Station staff with the necessary skills and knowledge to achieve all the plant performance targets with respect to safety, maintainability, availability, reliability and economic plant operation. The Contractor shall provide all formal training courses for the operator, maintenance and engineering staff at Medupi Power Station.

All training, except that of the up-front engineering training, provided by the Contractor shall be customised for Medupi Power Station and shall be directly applicable to the actual equipment and software supplied for the Works. Training will centre on the specific control and instrumentation system architecture, configuration, layout, equipment, software, HMI and design that the Contractor provides for the Works. Generalised training based on the Contractor’s generic control and instrumentation system architecture, HMI and design philosophies shall not be acceptable.

Facilities for training will be provided by the Employer at Medupi Power Station and will be a suitably sized air-conditioned room, to accommodate the trainees / trainer as well as trainee and trainer desks, a projector and flipchart or white board.

Practical hands-on training for each individual trainee shall form an integral part of each of the following categories.

Three categories of training are required:

3.2.3.10.2 TRAINING OF ENGINEERING STAFF

Training for the engineering personnel shall be provided in two separate stages:

• Up-front control and instrumentation system engineering training within 28 days of Contract Award. The Contractor shall provide for 6 participants from the Employer’s Engineering discipline.

• Additional engineering training (formal training) to be provided to 5 off additional Medupi Power Station engineers.

• Medupi specific engineering training for the engineering personnel in three different formats:

o Formal control and instrumentation system engineering courses as specified in the Key Date Schedule. The contractor shall provide 2 courses with 3 participants from the Employer’s Engineering discipline per course for a total number of participants of 6.

o Formal control and instrumentation system engineering courses, additional and separate to the Employer’s Engineering discipline, for the Medupi Power Station engineers. The Contractor shall provide 1 course with 5 participants from the Power Station engineers additionally.

o Engineering on job training at both the Contractor’s engineering facilities and Medupi Power Station from Systems Engineering to Hot Commissioning for



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both the Power Island 6 and Balance of Plant. Number of participants from the Employer: 3

The Contractor shall assess the Engineers participant for competency after each of the formal courses and the after the on job training before Hot Commissioning.

3.2.3.10.2.1 ENGINEERING STAFF TRAINING CONTENT

Engineering training includes, as a minimum:

• A system design philosophy which includes lessons and improvements from previous products, and operating and maintenance concepts.

• The system structure showing the hierarchy from the HMI, the Automation System and field devices. The structure must also show the hierarchy from subsystems, to modules, down to components (frequently used and critical ones) for both HMI and the Automation System. The aim is to be aware of the risks subjected by external changes in electronic technologies

• System Configuration and Documentation Control, including all necessary activities for system expansion/modification, and software storage.

• Power requirement calculation

• Development, debugging and testing of all software

• Software configuration and low-level programming

• Compilation, cross referencing and module binding the configuration drawings

• Installation, configuration and maintenance of all software packages forming part of the Works

• Graphic display design, development and configuration

• Data base generation, configuration and storage

• Network design, communication, configuration, security and expansion

• Process control loop tuning

• A system of monitoring system failure modes, effects and criticality to the business, for more proactive maintenance and lifecycle strategies

• Plant Information System engineering

• Alarm Management System engineering

• Third Party Interface system engineering where the third party system is supplied by Other Contractors

• Contractor supplied expert/third party systems

3.2.3.10.3 TRAINING OF MAINTENANCE STAFF

ASGI-SA TRAINING

The Contractor shall be responsible for sourcing the participants to comply with the ASGI-SA requirements under this contract. The Employer may also provide suitable participants to the Contractor to be included in the total required for ASGI-SA, if deemed necessary.



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The Contractor shall train these participants as his own resources and they shall be physically involved in design aspect, installation and commissioning of the control and instrumentation system.

The number of participant ASGI-SA resources by the Contractor shall be as follows:

System administration 2

Power Island 12

Balance of Plant 8

The demographic composition of the participants shall be as follows:

Race 80 % Black, Asian or Coloured

Gender 30 % Female

The Contractor shall test and declare the participants competent as being able to maintain the Medupi control and instrumentation system to the schedule in Table 10Table 10. The Employer has first right of refusal to accept the participants into his organisation.

The Contractor shall conduct formal control and instrumentation maintenance courses

Table 10: Schedule of trained maintenance staff available to the Engineer

02-Apr-10 01-Oct-11 01-Apr-12 01-Oct-12 01-Apr-13 01-Oct-13 01-Apr-14

Power Island 2 2 2 2 2 2

Common plant 2 2 2 2

System administration 1 1

The Contractor shall provide 2 formal control and instrumentation maintenance courses with 11 participants per course for a total of 22 participants.

In addition to the above the Employer shall have the option to second additional Employer’s maintenance trainees to the Contractor who shall integrate these staff into his organisation for training purposes.

MAINTENANCE TRAINING – POWER STATION MAINTENANCE STAFF

The Contractor shall train an additional 9 maintenance staff members and shall make provision for formal training as well as hands on training for these staff members.

The following training shall be provided

Maintenance technicians Power Island 4 off BOP 4 off System Administrators 1 off

The Contractor shall provide 2 formal control and instrumentation maintenance courses with 4 participants / 5 participants per course for a total of 9 participants. The training shall not be done at the same time as the ASGI-SA training are conducted but shall include the same sylabis as required for the ASGI-SA training.



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3.2.3.10.3.1 MAINTENANCE STAFF TRAINING CONTENT

Basic maintenance training includes, as a minimum:

• Familiarisation with the documentation forming part of the Works, including drawing configuration logic

• Hardware familiarisation

• Hardware configuration which includes the computers, processing modules, communication modules, I/O modules, power supply monitoring modules, network modules and all other peripheral equipment supplied as part of the Works.

• Hardware installation

• Control and instrumentation system software reloading

• Graphic display configuration

• Drawing and hardcopy report generation

• Network communication maintenance

• Operator interface familiarisation including keyboard and display functions, controls, alarms and messages

• System hardware maintenance through use and interpretation of diagnostic routines and error codes of on-line and off-line diagnostic software for the detection of faulty modules

• Module problem report retrieval

• Control and instrumentation system hardware maintenance training including the computers, programmable logic controllers, I/O modules, network modules and all other peripheral equipment supplied as part of the Works.

• Maintenance of field instrumentation, control valves and actuators

• Usage of engineering and diagnostic workstations

• Plant Information System maintenance

• Alarm Management System maintenance

Advanced maintenance training includes:

• Low level programming

• High level programming

• Network design

• Communication configuration

• Software configuration

• Programme storage and reloading

• Software directory management

• Software maintenance

• On-line system documentation maintenance

• Process control loop monitoring

• System Administration



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3.2.3.10.4 TRAINING OF OPERATORS AND SIMULATOR INSTRUCTORS /

ENGINEERING

The Contractor shall provide operator training in the form of formal courses prior to the Hot Commissioning of each Power Island.

Simulator instructors (2 off) shall be provided with detail formal HMI, control logic and control and instrumentation system training in addition to the specific simulator training related to process models and DCS emulation within the simulator software. The simulator instructors shall be trained to a level to allow full operation of the simulator, trouble shooting of simulator problems, and updaing process mechanical changes or DCS logic in the simulator model or emulation. . The simulators instructors shall also be utilised during the HMI graphic design as part of the design team. . The Contractor shall provide 1 formal simulator instructor training course with 2 participants from the Employer per course for a total of 2 participants.

Two Simulator engineers shall be provided with detail formal simulator development tool, HMI, control logic and control and instrumentation system training in addition to the specific simulator training related to process models and DCS emulation within the simulator software. The simulator engineers shall be trained to a level to allow full operation of the simulator, trouble shooting of simulator problems and updating process mechanical changes or DCS logic in the simulator model or emulation. The Contractor shall provide 1 formal simulator engineer training course with 2 participants from the Employer per course for a total of 2 participants.

In addition to the simulator instructor and engineering training, the Contractor shall also provide 6 formal operator training courses with 8 participants from the Employer per course for a total of 48 participants.

3.2.3.10.4.1 OPERATOR TRAINING CONTENT

Operator training includes, as a minimum:

• Familiarisation with the documentation provided as part of the Works, including drawing configuration logic

• Graphic display, design and configuration

• Operator interface familiarisation including keyboard and display functions, plant control, plant monitoring, navigation, alarms, messages, creation and use of operator configurable displays and operator assignable trends as well as retrieval and printing of plant logs

• Process control and operating philosophies

• Use of the HMI during various types of Power Island start-up and shutdown

• Use of the HMI during load following

• Use of the HMI during emergency operations

3.2.3.10.4.2 SIMULATOR INSTRUCTOR / ENGINEERING CONTENT

The Contractor shall conduct training sessions for instructors who will operate the simulator and engineers who will maintain, update and modify the simulator.

The instructor training includes the following, as a minimum:

• Overview of the hardware



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• Overview of the software

• Overview of all simulator models including process and controls models

• Review of instructor functions

• Hands on practice using the system

• Hands on practice building malfunctions

The simulator engineering training includes the following, as a minimum:

• Details of the hardware

• Details of the software

• Details of the all simulator models including process and controls models

• Details of the DCS logic/graphic emulation within the simulator

• Review of instructor functions

• Hands on practice using the system

• Modification and building of models

• Hands on practice building models

• Details of diagnostic software

• Removal and reinstallation of specific components

• Hands on practice troubleshooting

• Working knowledge of the simulator development tool to modify, faultfinding of the simulator process and control models

3.2.3.10.5 TRAINING DOCUMENTATION

The Contractor shall provide all course material including manuals in accordance with the requirements of VGB 171e Appendix 14 – Project Standards. The course material shall be in English and shall include all third party documentation.

The Contractor shall submit draft documentation of all training course as per the Key date Schedule requirements prior to commencement of the each training course. The Engineer will review the documentation and request modification or additions to the training course, which shall be incorporated by the Contractor. Final documentation incorporating all comments and modifications proposed by the Engineer shall be supplied to the Engineer as per the Key date Schedule requirements prior to commencement of training. Training documentation shall address specific training objectives and shall not be simply reference manuals or extracts of other documentation.

A copy of the training documentation is supplied for each trainee with an additional 3 hardcopy master sets and one electronic copy for the Employer’s library and training department.

All training documentation provided by the Contractor shall be customised for Medupi Power Station. The training documentation will contain the specific control and instrumentation system architecture, configuration, layout, software, equipment, HMI and design provided by the Contractor as part of the Works.



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Training manuals shall be continuously updated by the Contractor up to the Completion of the whole of the Works.

3.2.3.10.6 PARTICIPATION OF EMPLOYER STAFF

The Employer will second three engineers to work with the Contractor during the design, installation and commissioning stages of the contract.

The Employer’s engineering staff seconded to the Contractor shall not be viewed as part of the Contractor’s resources necessary to provide the Works. The Engineer may withdraw such staff at any time.

3.2.3.10.7 CERTIFICATION OF EMPLOYER STAFF COMPETENCE

The Contractor shall after an agreed “on-job” training period and successful completion of the training certify the Employer’s ASGI-SA developed staff as being competent to maintain the relevant systems.



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3.2.3.11 LICENSES AND CONFIDENTIALITY

3.2.3.11.1 LICENSES

All licenses required by the Employer covering the equipment, standard software and application software, forming part of the Works, shall be included as part of the Works.

Licenses for the equipment and software provided shall include the Contractor’s Sub-Contractors or third party licenses and shall be unlimited and valid for the entire life of the control and instrumentation system. All licenses are site licenses for use at Medupi Power Station Site.

3.2.3.11.2 UPGRADES

The Contractor shall at the start of the last Power Island, update all preceding Power Islands with the Contractor’s latest release of the system software versions including software patches, hardware firmware versions or Service Packs of the system software. Where updates cannot be performed online they shall occur during General Outages.

Application software improvement (logics) shall be back-fitted to all Power Islands and

BOP as requested by the Engineer.

For the duration of the project all versions of the system software installed shall be

internationally supportable by the parent company (OEM) support center.

3.2.4 WORKS EQUIPMENT AND SERVICES PROVIDED BY THE ENGINEER

3.2.4.1 FIELD EQUIPMENT FOR ALL PLANT AREAS

The scope of equipment and services provided by the Employer for the field equipment is defined in the following Specification documents:







3.2.4.2 SIGNAL INTERFACES

The Employer will provide systems, which the Contractor treats as a 'Black Box'. These systems shall interface into the Contractor’s control and instrumentation system. The Employer shall supply the connection details for the interfaces.

These are defined in the following documents:





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3.2.4.3 ELECTRICAL SWITCHGEAR

The Employer shall provide all electrical switchgear. The control interface between LV and MV switchgear shall be hardwired as defined in the following documents:




3.2.4.4 SWITCHGEAR INTERPOSING RELAYS

The Employer shall provide the interposing relays for all electrical drives that are switched by the control and instrumentation system from the Employer supplied switchgear.

These are defined in the following Specification documents:




3.2.4.5 POWER SUPPLIES

The Employer shall supply bulk 400 V AC from two different distribution board to all the Power Island battery charger rooms, station battery charger rooms, SSB battery charger rooms and WTP battery charger rooms. The Contractor shall supply redundant 220 V AC battery systems with each redundant bank having the capability to supply the full load for 4 hours. The Contractor shall supply the chargers, inverters and power supplies to the Engineer’s specification and to match the make and model to that supplied by the Employer for other purposes. The details shall be clarified during the Systems Engineering phase. The make and model of the power equipment shall be submitted to the Engineer for approval.

The Employer shall supply bulk 400 V AC from two different distribution board to all the Balance of Plant substations. The Contractor shall supply redundant 220 V AC UPS systems with integrated NiCad or NiMos batteries to meet the load requirements of his equipment in the specific substation. Each of the members of the redundant UPS system shall be capable to supply the full load for at least 4 hours.

3.2.4.6 CABLING

The Engineer will route design and the Employer will supply primary racking throughout the power station. The Contractor shall incorporate the primary racking in its cable routing design and utilise the primary racking for the running of trunk and bus cables forming part of the works. The detail routing of the primary racking shall be clarified during the Clarification Phase.



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3.2.4.7 CONTROL ROOMS AND EDCR

The Engineer shall be responsible for the supply and installation of civil and architectural work, including finishes to all control rooms. The Contractor shall provide the Works as per the Appendix 9 – Limits of Supply and Services.

The Employer shall provide the following as part of the Works:

• Floor tiling (Designed by the Contractor as part of the ergonomic studies)

• Ceilings to suit the environment (Designed by the Contractor as part of the ergonomic studies)

• Partitioning and doors (Designed by the Contractor as part of the ergonomic studies)

• Wall finishes (Designed by the Contractor as part of the ergonomic studies)

• Access for cabling (Designed by the Contractor as part of the ergonomic studies)

• Air conditioning and ventilation

• Lighting (Designed by the Contractor as part of the ergonomic studies)

3.2.4.8 EQUIPMENT ROOMS & DC POWER SUPPLY ROOMS

The Employer shall provide control and instrumentation equipment rooms in the Auxiliary bay and in the sub-stations.

The Contractor’s and the Engineer‘s final requirements for the various equipment rooms will be clarified and if need be modified during the system engineering technical clarification meetings.

The Engineer will be responsible for the equipment room civil and architectural work, including finishes.

The Contractor shall provide the works as per the Appendix 9 – Limits of Supply and Services.


• Floor tiling(Designed by the Contractor as part of the ergonomic studies)

• Ceilings to suit the environment(Designed by the Contractor as part of the ergonomic studies)

• Partitioning and doors(Designed by the Contractor as part of the ergonomic studies)

• Wall finishes(Designed by the Contractor as part of the ergonomic studies)

• Access for cabling(Designed by the Contractor as part of the ergonomic studies)

• Air Conditioning and Ventilation


3.2.4.9 TEMPORARY AND PERMANENT SIMULATOR SUITES

The Engineer shall be responsible for the Temporary and Permanent Simulator Suites’ civil and architectural work, including finishes.

The Contractor shall provide the Works as per the LOSS diagrams.



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• Floor tiling(Designed by the Contractor as part of the ergonomic studies)

• Ceilings to suit the environment(Designed by the Contractor as part of the ergonomic studies)

• Partitioning and doors(Designed by the Contractor as part of the ergonomic studies)

• Wall finishes(Designed by the Contractor as part of the ergonomic studies)

• Access for cabling(Designed by the Contractor as part of the ergonomic studies)

• Air Conditioning and Ventilation


3.2.4.10 INFORMATION SYSTEM

The Employer shall make available the station business LAN and supplies the LAN connection points for connection to the Station Information System provided by the Contractor. The firewalls shall be provided by the Employer.

3.2.5 COMPLETION

3.2.5.1 WORK TO BE PROVIDED BY THE CONTRACTOR FOR COMPLETION

3.2.5.1.1 DESIGN FREEZE

The Contractor shall provide the system engineering and design stage documentation for the Works in accordance with the Works as specified in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) .

3.2.5.1.2 FACTORY ACCEPTANCE TEST (FAT)

The Contractor shall provide the Power Island 6 ,Balance of Plant and Water Treatment Plant FAT for the Works as specified in Appendix 15 – Minimum Assessment and Testing Requirements.

3.2.5.1.3 SITE INTEGRATION TEST (SIT)

The Contractor shall provide the SIT for the Works as specified Appendix 15 – Minimum Assessment and Testing Requirements. The Contractor shall issue all documents as listed in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) to the Engineer for acceptance.

3.2.5.1.4 OPERATIONAL ACCEPTANCE TEST (OAT)

The Contractor shall provide the OAT for the Works as specified in Appendix 15 – Minimum Assessment and Testing Requirements. The Contractor shall issue all commissioning documents as listed in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) to the Engineer for acceptance.

3.2.5.1.5 CAPABILITY ACCEPTANCE TEST (CAT)

The Contractor shall provide the OAT for the Works as specified in Appendix 15 – Minimum Assessment and Testing Requirements.



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The Contractor shall issue all documents as listed in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) to the Engineer for acceptance.

3.2.5.1.6 POWER ISLAND COMPLETION

The Contractor shall perform the capability tests for the Power Island as Appendix 15 – Minimum Assessment and Testing Requirements. Completion takes place after the Engineer has accepted the documents submitted by the Contractor, as specified in Appendix 1 – Vendor Documentation Submittal Schedule (VDSS) . The responsibility for operation and routine maintenance for each section passes to the Engineer at Completion.

3.2.5.1.7 SIMULATOR

The Contractor shall perform the simulator FAT, SIT and ‘As Built’ Acceptance tests and inspections as specified in Appendix 15 – Minimum Assessment and Testing Requirements.

3.2.6 CONTRACTORS ORGANISATION

The Contractor shall submit a project organisational chart to the Engineer for approval.

The Contractor’s organisational chart shall indicate all project and engineering resources that will be utilised for the complete project. In particular the organisational chart shall indicate the process and process control resources that will be utilised for each of the Project Methodology Phases.

The Contractor shall indicate the process and control and instrumentation experts as defined in Section 3.2.3.4.2 in the organisational chart.

2009-11-27 3.2

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Transcript of 2009-11-27 3.2