C3.1 ECC3 Employer's Works Information ECC3... · Web viewThe downstream flange of the valve (by...

ESKOM HOLDINGS SOC LIMITED CONTRACT NUMBER _____________

TUTUKA POWER STATION ESP TO FFP RETROFIT PROJECT

PART 3: SCOPE OF WORK

Document reference

Title No of pages

This cover page 1

C3.1 Employer’s Works Information 203

C3.2 Contractor’s Works Information 1

Total number of pages 205

PART C3: SCOPE OF WORK 1 C3 ECC3 COVER PAGE



C3.1: EMPLOYER’S WORKS INFORMATION

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

C3.1: Employer’s works Information.............................................................................................................2

1 Description of the works.....................................................................................................................12

1.1 Executive overview......................................................................................................................... 12

1.1.1 Excluded from the Works..........................................................................................................14

1.2 Employer’s objectives and purpose of the works............................................................................14

1.2.1 FFP Performance Evaluation and Performance Guarantees....................................................16

1.2.2 Reuse of existing plant..............................................................................................................17

1.2.3 Limits of Supply and Services (LOSS)......................................................................................18

1.2.4 Interface with Others.................................................................................................................19

1.3 Interpretation and terminology........................................................................................................22

2 Management and start up.................................................................................................................... 24

2.1 Management meetings................................................................................................................... 24

2.2 Documentation control....................................................................................................................27

2.2.1 General..................................................................................................................................... 27

2.2.2 Document Control and Management........................................................................................27

2.2.3 Documentation Pre-submission................................................................................................27

2.2.4 Process for Documentation Submission....................................................................................28

2.2.5 Documentation Recording.........................................................................................................29

2.2.6 Documentation Review and Turn-around..................................................................................29

2.2.7 Email Subject............................................................................................................................ 30

2.2.8 Data........................................................................................................................................... 30

2.2.9 Plant Coding and Labelling.......................................................................................................30

2.3 Health and safety risk management................................................................................................31

2.3.1 Safety of Worker.......................................................................................................................32

2.3.2 Fire Protection........................................................................................................................... 33

PART C3: SCOPE OF WORK PAGE 2 C3.1 ECC3 EMPLOYER’S WORKS INFORMATION



2.3.3 First Aid..................................................................................................................................... 33

2.3.4 Housekeeping........................................................................................................................... 33

2.3.5 Barricading................................................................................................................................ 33

2.3.6 Radiographic Examinations.......................................................................................................33

2.3.7 Permit to Work System..............................................................................................................33

2.4 Environmental constraints and management..................................................................................34

2.5 Quality assurance requirements.....................................................................................................34

2.5.1 General..................................................................................................................................... 34

2.5.2 Quality Management documents requirements.........................................................................34

2.5.3 Reporting on quality performance.............................................................................................35

2.5.4 Quality Responsibility................................................................................................................35

2.5.5 Inspections................................................................................................................................ 36

2.5.6 Non Conformances and Defects...............................................................................................36

2.5.7 Quality Reporting......................................................................................................................37

2.5.8 Preservation, shipping and transportation.................................................................................37

2.6 Programming constraints................................................................................................................37

2.6.1 Planning Methodology and Programme Levels.........................................................................39

2.6.2 Planning Schedules..................................................................................................................40

2.6.3 Time Analysis............................................................................................................................ 41

2.6.4 Planning Networks....................................................................................................................41

2.6.5 Time Reporting..........................................................................................................................42

2.6.6 Reporting on Remaining Duration.............................................................................................42

2.6.7 Actual Dates.............................................................................................................................. 42

2.6.8 Progress Reporting during Provision of the Works....................................................................42

2.6.9 Daily Progress Report...............................................................................................................43

2.6.10 Weekly Progress Report...........................................................................................................43

2.6.11 Monthly Progress Report...........................................................................................................43

2.6.12 General Planning Report...........................................................................................................44

2.6.13 Critical Activities Report............................................................................................................44




2.6.14 Planner Requirements...............................................................................................................44

2.7 Contractor’s management, supervision and key people.................................................................44

2.8 Invoicing and payment....................................................................................................................45

2.8.1 General..................................................................................................................................... 45

2.8.2 Foreign Portion Invoicing...........................................................................................................46

2.8.3 Import Invoices.......................................................................................................................... 46

2.9 Insurance provided by the Employer...............................................................................................46

2.10 Contract change management........................................................................................................46

2.10.1 Contract changes and contract Scope......................................................................................47

2.10.2 Administrative changes.............................................................................................................47

2.10.3 Substantive changes................................................................................................................. 47

2.10.4 General Principles of contract change management.................................................................47

2.10.5 Costs......................................................................................................................................... 48

2.10.6 Impact Assessment...................................................................................................................48

2.10.7 Project Manager’s right of acceptance of contract changes......................................................48

2.10.8 Contractor’s right of acceptance of proposed changes.............................................................49

2.10.9 Emergency Instruction contract changes..................................................................................49

2.10.10 Authorisation of contract change...............................................................................................49

2.10.11 Communications.......................................................................................................................49

2.11 Provision of bonds and guarantees.................................................................................................49

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

Contractor................................................................................................................................................... 50

2.13 Training workshops and technology transfer..................................................................................50

3 Engineering and the Contractor’s design..........................................................................................51

3.1 Employer’s design........................................................................................................................... 51

3.1.1 Employer's design approach.....................................................................................................51

3.1.2 Fabric Filter Plant (FFP) Electrical System Design...................................................................64

3.1.3 Cleaning Air Equipment Plant Electrical System Design...........................................................66

3.1.1 FFP and Cleaning Air Equipment Plant C&I System Design.....................................................67




3.1.2 FFP operating and control philosophy.......................................................................................68

3.2 Parts of the works which the Contractor is to design......................................................................69

3.2.1 Flue Gas Expansion Joints........................................................................................................70

3.2.2 FFP Compartment Inlet Dampers.............................................................................................70

3.2.3 FFP Compartment Outlet Dampers...........................................................................................70

3.2.4 FFP Implosion Dampers............................................................................................................71

3.2.5 FFP Compartment.....................................................................................................................71

3.2.6 FFP Casing Foundations...........................................................................................................72

3.2.7 Access doors............................................................................................................................. 73

3.2.8 FFP tube sheet..........................................................................................................................73

3.2.9 FFP Pulse Air Header...............................................................................................................73

3.2.1 FFP Valves................................................................................................................................ 74

3.2.2 FFP Pulse Air Header Expansion Joint.....................................................................................74

3.2.3 Blow pipes and J-pipes.............................................................................................................74

3.2.4 Penthouse................................................................................................................................. 75

3.2.5 Filter Bag Cages.......................................................................................................................75

3.2.6 FFP Hoppers............................................................................................................................. 76

3.2.7 FFP Pre-coating System...........................................................................................................76

3.2.8 Compartment Ventilation System..............................................................................................77

3.2.9 Jib crane and Hoists.................................................................................................................. 78

3.2.10 Site Construction Workshop......................................................................................................78

3.2.11 Slide Bearings........................................................................................................................... 80

3.2.12 Pulse Air Receiver Tank Bases.................................................................................................80

3.2.13 Control Power Supplies.............................................................................................................81

3.2.14 FFP Earthing and Lightning Protection......................................................................................81

3.2.15 FFP Area Lighting and Small Power.........................................................................................81

3.2.16 Electrical Equipment Detail Design...........................................................................................81

3.2.17 Low Voltage Switchgear............................................................................................................82

3.2.18 Cabling and Cable Racking.......................................................................................................82




3.2.19 Diesel Generator Boards Modification.......................................................................................83

3.2.20 Cleaning Air Equipment System................................................................................................83

3.2.21 Cleaning Air Compressor Plant Control System Design (Common Plant DCS)........................87

3.2.22 FFP Control System Design......................................................................................................88

3.2.23 Field Equipment Design............................................................................................................89

3.2.24 Insulation and Lagging..............................................................................................................89

3.3 Procedure for submission and acceptance of Contractor’s design.................................................89

3.3.1 Design Review Documentation.................................................................................................89

3.3.2 Engineering Change Procedure................................................................................................90

3.3.3 Time Required for Acceptance of Designs................................................................................90

3.4 Use of Contractor’s design..............................................................................................................91

3.5 Design of Equipment....................................................................................................................... 91

3.6 Equipment required to be included in the works.............................................................................91

3.6.1 Special Tools............................................................................................................................. 92

3.7 As-built drawings, operating manuals and maintenance schedules................................................92

3.7.1 2D drawings and 3D Models.....................................................................................................92

4 Procurement......................................................................................................................................... 94

4.1 People............................................................................................................................................. 94

4.1.1 Minimum requirements of people employed on the Site............................................................94

4.1.2 BBBEE and preferencing scheme.............................................................................................94

4.1.3 Skills Development, Local Content and Local Production.........................................................95

4.1.4 Localisation Compliance...........................................................................................................95

4.1.5 Skills Development....................................................................................................................95

4.1.6 Job Creation.............................................................................................................................. 95

4.2 Subcontracting................................................................................................................................ 96

4.2.1 Preferred subcontractors...........................................................................................................96

4.2.2 Enterprise Development (ED)...................................................................................................98

4.2.3 Subcontract documentation, and assessment of subcontract tenders......................................98

4.2.4 Limitations on subcontracting....................................................................................................98




4.2.5 Attendance on subcontractors...................................................................................................98

4.3 Plant and Materials......................................................................................................................... 98

4.3.1 Quality....................................................................................................................................... 98

4.3.2 Plant & Materials provided “free issue” by the Employer...........................................................99

4.3.3 Contractor’s procurement of Plant and Materials......................................................................99

4.3.4 Spares and consumables........................................................................................................102

4.4 Tests and inspections before delivery...........................................................................................103

4.4.1 FFP Cages Inspection Criteria................................................................................................103

4.4.2 Poppet dampers (FFP Outlet and Implosion Dampers)...........................................................104

4.4.3 Blow pipes and J pipes............................................................................................................105

4.4.4 Tube sheet.............................................................................................................................. 105

4.4.5 Louver Dampers (FFP Compartment Inlet Dampers)..............................................................106

4.4.6 Valves..................................................................................................................................... 107

4.4.7 Actuators................................................................................................................................. 107

4.4.8 Pulse Air Headers................................................................................................................... 107

4.4.9 Pre Factory Acceptance Test..................................................................................................108

4.4.10 Factory Acceptance Test (FAT)..............................................................................................108

4.5 Marking Plant and Materials outside the Working Areas...............................................................109

4.6 Contractor’s Equipment (including temporary works)....................................................................109

5 Construction....................................................................................................................................... 110

5.1 Temporary works, Site services and constructions constraints.....................................................110

5.1.1 Employer’s Site entry and security control, permits, and Site regulations...............................110

5.1.2 People restrictions on Site; hours of work, conduct and records.............................................110

5.1.3 Health and safety facilities on Site..........................................................................................110

5.1.4 Title to materials from demolition and excavation...................................................................110

5.1.5 Cooperating with and obtaining acceptance of Others............................................................110

5.1.6 Publicity and progress photographs........................................................................................110

5.1.7 Contractor’s Equipment...........................................................................................................110

5.1.8 Existing premises, inspection of adjoining properties and checking work of Others................110




5.1.9 Construction Sequencing Video and Mock-up........................................................................110

5.1.10 Excavations and associated water control..............................................................................110

5.1.11 Site services and facilities.......................................................................................................110

5.1.12 Facilities provided by the Contractor.......................................................................................110

5.1.13 Contractor’s Equipment...........................................................................................................110

5.1.14 Control of noise, dust, water and waste..................................................................................110

5.1.15 Existing premises, inspection of adjoining properties and checking work of Others................110

5.1.16 Giving notice of work to be covered up...................................................................................110

5.1.17 Hook ups to existing works......................................................................................................110

5.2 Completion, testing, commissioning and correction of Defects.....................................................125

5.2.1 Work to be done by the Completion Date................................................................................125

5.2.2 Use of the works before Completion has been certified..........................................................125

5.2.3 Materials facilities and samples for tests and inspections.......................................................125

5.2.4 Commissioning........................................................................................................................126

5.2.5 Start-up procedures required to put the works into operation..................................................129

5.2.6 Take over procedures.............................................................................................................129

5.2.7 Access given by the Employer for correction of Defects.........................................................129

5.2.8 Performance tests after Completion........................................................................................129

5.2.9 Training and technology transfer.............................................................................................130

6 Plant and Materials standards and workmanship...........................................................................132

6.1 Investigation, survey and Site clearance.......................................................................................132

6.1.1 Site survey.............................................................................................................................. 132

6.1.2 Geotechnical Investigation......................................................................................................132

6.1.3 Ground control survey.............................................................................................................134

6.2 Civil, structural and building works................................................................................................134

6.2.1 Fabrication scope of the works................................................................................................135

6.2.2 Structural steel work................................................................................................................135

6.2.3 Concrete works.......................................................................................................................145

6.3 Electrical engineering works.........................................................................................................151




6.3.1 Included in Electrical scope.....................................................................................................152

6.3.2 Voltage Levels......................................................................................................................... 153

6.3.3 Cabling and Racking...............................................................................................................153

6.3.4 Low Voltage Switchgear..........................................................................................................155

6.3.5 Medium Voltage Motors..........................................................................................................156

6.3.6 Low Voltage Motors................................................................................................................156

6.3.7 Transformers........................................................................................................................... 157

6.3.8 Lighting and Small Power........................................................................................................157

6.3.9 Earthing and Lightning Protection...........................................................................................159

6.3.10 Control Power Supplies...........................................................................................................160

6.3.11 Variable Speed Drives (VSDs)................................................................................................160

6.4 Mechanical engineering works......................................................................................................161

6.4.1 Painting and Preservation.......................................................................................................161

6.4.2 Nameplates and Identification System....................................................................................162

6.4.3 Welding Requirements............................................................................................................162

6.4.4 Fabric filter cages.................................................................................................................... 163

6.4.5 Dampers.................................................................................................................................. 164

6.4.6 Valves..................................................................................................................................... 167

6.4.7 FFP Tube sheet......................................................................................................................171

6.4.8 Flue Gas Ducting....................................................................................................................174

6.4.9 Flue Gas expansion Joints......................................................................................................175

6.4.10 Compartment Ventilations Fans and System..........................................................................176

6.4.11 Jib Crane and Hoists...............................................................................................................177

6.4.12 FFP pre-coating system..........................................................................................................178

6.4.13 FFP Hoppers........................................................................................................................... 179

6.4.14 FFP Access Doors (Compartment and Flue)..........................................................................180

6.4.15 Fire Protection......................................................................................................................... 181

6.5 Control and Instrumentation engineering Works...........................................................................181

6.5.1 Introduction............................................................................................................................. 181




6.5.2 Control and Instrumentation....................................................................................................182

6.5.3 Control System........................................................................................................................184

6.5.4 Boiler Protection System (BPS)..............................................................................................185

6.5.5 Human Machine Interface (HMI).............................................................................................185

6.5.6 Plant Information System (PIS)...............................................................................................186

6.5.7 Data Acquisition......................................................................................................................186

6.5.8 Simulator Plant Requirements.................................................................................................186

6.5.9 Cleaning Air Equipment Plant System Design........................................................................186

6.5.10 Field Equipment and Cabling Requirements...........................................................................187

6.5.11 Power Supply Requirements...................................................................................................188

6.5.12 Impulse Piping and Accessories.............................................................................................188

6.5.13 Licences.................................................................................................................................. 188

6.5.14 Process Control and IT works.................................................................................................189

6.6 Cleaning Air Equipment System...................................................................................................189

6.6.1 Pipe spool fabrication..............................................................................................................190

6.6.2 FFP Pulse Air Headers............................................................................................................191

6.6.3 Pulse air header expansion joints (flexible hose)....................................................................193

6.6.4 Blow pipes and J-pipes...........................................................................................................194

6.6.5 Piping Supports....................................................................................................................... 196

7 List of drawings.................................................................................................................................. 197

7.1 Drawings issued by the Employer.................................................................................................197

7.2 Drawings Issued by the Contractor...............................................................................................203

C3.2 Contractor’s Works Information.......................................................................................................205

List of Tables

Table 1: Meetings Schedule.......................................................................................................................... 25

Table 2 : Minimum Frequency of Inspection for J pipes and Blow Pipes......................................................105

Table 3 : Pulse Air Header Inspection Frequency........................................................................................107




Table 4: Steelwork codes and standards......................................................................................................135

Table 5: Specification data associated with SANS 2001-CS1......................................................................136

Table 6: Specification data associated with SANS 1200 HA........................................................................142

Table 7: Specification data associated with SANS 1200 HB........................................................................142

Table 8: Specification data associated with SANS 1200 HC........................................................................143

Table 9: Specification data associated with SANS 2001-CC1.....................................................................145

Table 10: Concrete temperature during early life.........................................................................................150

Table 11 : FFP Access Door Supply Quantity..............................................................................................180

Table 12 : Pulse Air Header Expansion Joint (flexible hose) Specification...................................................193




1 Description of the works

1.1 Executive overview

Tutuka Power Station is situated approximately 140 km from Johannesburg in Mpumalanga province, South

Africa. Tutuka is a coal fired power station with six operating units; of 609 MW each. Each unit is fitted with

a dry Electrostatic Precipitator (ESP) as particulate abatement technology. Each ESP has two casings with

two parallel chambers per casing. In order to comply with National Environmental Management – Air Quality

Act, 2004 [Act 39/2004], Notice 248; particulate matter emissions limit of 50 mg/Nm3 the ESPs need to be

retrofitted to FFP’s by the Contractor as per the Employers design, which was created in partnership with

Babcock & Wilcox (B&W), in the existing ESP casings.

The Tutuka Power Station estimated remaining life of the plant is forty years and the works, by the

Contractor is required for the remainder of the life of Tutuka Power Station.

The refurbishment from ESP to FFP will be done in any of the first three available units.

The Contractor constructs the FFP system and performs all modifications to the existing plant as required by

the Employers design. The FFP system design provides implosion protection and a bag pre-coating system.

The Contractor caters for and installs access to all areas of the plant, expansion joints, ducting, dampers,

instrumentation etc. The Contractor performs insulation and cladding as per the Employer's specifications.

All auxiliary elements associated with the FFP is provided and installed/constructed by the Contractor. This

includes (but not limited to), items such as Civil and Structural i.e. foundations, Protection systems i.e.

vibration monitoring system, Mechanical auxiliary systems i.e. expansion joints, valves, fans, piping,

Electrical requirements i.e. cabling and instrumentation. Refer to Section 6 of this document for

requirements.

The Contractor provides a cleaning/pulsing air equipment system which delivers pulse and instrument air for

the cleaning of the FFP bags. The cleaning/pulsing air equipment includes compressors, air dryers, cooling

system, air receivers, piping, valves and all other auxiliaries as per the Employers design.

The Contractor provides all civil and structural portions of the works as per this Works Information.

The Contractor designs, constructs and furnishes a site workshop. The Contractor uses the site workshop

for site construction/erection of the modularised FFP compartments.

Existing plant data and DEA drawings are provided by the Employer. A fully integrated, working FFP system

is constructed which meets safety, reliability and operability criteria and performs all control, safety and

protection functions and supervisory functions as detailed within the Works Information.

Due to the ESP to FFP retrofit the Dust Handling Plant (DHP) must be upgraded and the ID Fan size and

technology needs to change to sustain the required negative pressure within the boiler. The upgrade of the

DHP and the replacement of the ID Fans will be performed by Others , during the same outage period. The

DHP contractor will construct a FFP and DHP compressor house and furnish it with the DHP project




equipment. The Contractor installs all FFP cleaning air equipment in the FFP and DHP compressor house as

per the Works Information.

The Contractor integrates the Control and Instrumentation (C&I) system into each unit control system, as per

Employer’s design. The Contractor implements and programs the logics in to the DCS as per the Employer’s

design.

The Contractor subcontracts Yokogawa, the OEM of the Outside Plant DCS, and ABB, the OEM of the Unit 4

- 6 DCS, to ensure the correct implementation and commissioning of the FFP cleaning air equipment plant

control system and the FFP control system respectively. Furthermore the Contractor interfaces with the

Unit1 - 3 C&I refurbishment/replacement project to ensure the implementation and commissioning of the FFP

system in the new DCS.

The Contractor provides for the engineering design, manufacture and fabrication detailing, factory testing,

supply, storage, delivery, off-loading, erection, installation, site testing and commissioning of new LV

switchgear, modify existing LV switchgear (380V Diesel Gen Boards), new cabling and racking (including

terminations and joints), uninterruptable power supplies, LV motors, earthing and lightning protection,

lighting, small power and transformers to support the ESP to FFP Retrofit.

The Contractor's works is in accordance with the relevant South African Standards, Regulations and Codes

of Practice. The design of the works and specifications of the Plant and Materials, methods and erection is

carried out by a suitably qualified registered professional engineer, registered with the Engineering Council of

South Africa.

The FFP Bags will be supplied by the Employer, the Contractor installs and stores the FFP bags.

The works includes design detailing, manufacture, fabrication, surface protection, quality control,

procurement, handling, shipment and transport to/from site, storage, unloading, construction and erection,

painting and finishing, quality control, installation, testing, commissioning (optimisation) and handover of

Plant and Material, and special equipment for a fully operational and functional multi-compartment FFP (any

omitted item that the Contractor finds necessary to include is included) (including; C&I, Electrical, Mechanical

and Civil/Structural).

The works also include,

dismantling, decommissioning and removal from Site and disposal of all associated equipment,

material and systems associated with the ESP to FFP Retrofit design as per the Works Information,

to an area specified by the Employer (including removal of scrap material);

development and supply of fabrication, erection and as-built drawings to the Project Manager for

acceptance. The works includes any special tools or Equipment required to perform maintenance

and operation activities, and is handed over to the Employer on completion and

all spares required as per the Works Information.




1.1.1 Excluded from the Works

The Contractor is not responsible for:

Supply of the FFP bags.

Construction of the ID fan upgrade, support structure and foundation.

Construction of the Dust Handling Plant upgrade.

Construction of roads.

3.3kV Cleaning Air Equipment Boards A and B.

The Substation Automation System (SAS) interface for all LV switchgear that forms part of the

works.

Termination of all MV power cables on MV switchgear.

Procurement of IEDs to be used in the incomers and bus-section panels of all LV switchgear that

form part of the works.

An actual HMI screen (Hardware) for a unitised FFP and cleaning air equipment plant system.

Linking / interfacing the new FFP HMI in Unit 1 – 3 to the existing PIS for data storage and long term

information.

All Unit 1 - 3 trunk cabling and associated racks/trays from junction boxes in the field to the

DCS/Marshalling control cubicles; and Unit 1 - 3 trunk cabling from the new FFP switchgear to the

DCS/Marshalling control cubicles.

GPS in Unit 1-3

Unit 1-3 control wiring from MV/LV Switchgear to the new DCS.

Control wiring from the MV switchgear to the outside plant DCS.

Integrating the Contractor’s drawings in the Unit 1-3 control system.

Construction of the FFP outlet duct support structure.

Manufacture/procure, transport, supply, install, test and commission the lighting and small power

requirements for the new compressor house building.

1.2 Employer’s objectives and purpose of the works

The purpose of this Works Information is for the engineering design, procurement, de-commissioning,

demolition, construction and commissioning of a complete Tutuka ESP to FFP Retrofit Project. The installed

FFP will be according to the design performed by the Employer under the licensing agreement with B&W.

The design performed with B&W provides a baseline for the FFP system and components, acting as a formal

basis of design which allows the Contractor to proceed with construction activities as per the works.

The Contractor provides the works such that the FFP operates as stated/intended in this section, Section 3.1

and as intended by the Employers design. Refer to O&M Manual, Appendix K.

The Contractor dismantles the existing ESP in such a way to be able to utilize sections of the existing ESP

casings. Refer to Appendix O.




The Contractor supplies Plant and Material, special tools, provides field erection, commissioning and is

responsible for coordinating the work with Others.

The FFP for each unit is installed during a 120 day outage (breaker open to breaker closed). All parts of the

works are completed before breaker closed. The Contractor only performs work after breaker closed if the

Contractor has obtained acceptance from the Project Manager in writing.

The FFP cleaning/pulse air system is designed such that the FFP cleaning/pulse air system Plant and

Material is installed, by the Contractor, in the FFP and DHP compressor house, designed and constructed by

Others.

FFP filter bags will be cleaned by compressed air supplied by the cleaning/pulse air compressors.

Existing ESP hoppers are reused to the maximum extent possible with modification as required, as per

Employer design.

The Contractor carries out manufacturing and proves standards of quality by inspections at every stage of

the project. The Contractor installs and checks the quality of installation of the fabric filter bags.

The C&I system design is such that the system Plant and Materials is installed and integrated into the control

system by the Contractor in Unit 4-6 and the common outside plant. The C&I system design for Unit 1-3 is

such that the Contractor interface with Others in Unit 1-3 to fully realise a complete functional, operational

plant system. The C&I system design takes into consideration the appropriate redundancies to match the

mechanical processes, and minimise the effects of equipment failure with the primary function such that no

individual C&I fault, or no two concurrent faults will endanger the safety of the people, plant, or jeopardise the

integrity of the major plant.

The electrical systems designs have been developed in order to adequately support the mechanical process

design requirements. All electrical reticulation, not supplying process loads, will be monitored and controlled

on the Substation Automation System (SAS) which will be provided by Others and coordinated with the

Contractor’s work. The SAS will only be used to control the main incomers, transformer feeders, LV bus

sections and LV board to board feeders.

The Contractor takes note of the climatic conditions encountered at Tutuka Power Station. The Plant and

Materials design and equipment design, specification, and location of components are taken into

consideration to ensure that the Plant and Material can tolerate the site meteorological design conditions,

including instruments and sensors. Refer to Appendix C.

The Contractor is responsible for determining the extent of removal, replacement, repair, or extent of new

handrails, staircases and platforms in the work s and developing appropriate design and erection drawings.

Permanent access and platforms are provided to access all pre-coating and test port connections. Access

and platforms meet all the regulatory requirements and provides a stable working area for all anticipated

work to be performed in these areas.

As part of the Employers design, drawings has been developed for site arrangement and construction

facilities and DEA’s, the Contractor provides manufacturing, fabrication, erection and as-built drawings.




1.2.1 FFP Performance Evaluation and Performance Guarantees

The Contractor provides Plant and Material that meets the requirements, tolerances and specifications as set

out in the Works Information. The Contractor in particular meets the guarantees below.

If the guarantees are not met, the Contractor either take steps to meet the guarantee or replace the Plant

and Material such that guarantees are met.

1.2.1.1 Jib cranes and hoists performance guarantees

The Contractor supplies Plant and Material that meets the specified requirements over the stated range of

operating conditions specified in Appendix C and the requirements in Appendix F.

1.2.1.2 Poppet Damper performance guarantee

The Contractor guarantees that the Plant and Material supplied meets the guarantees across the range of

operation and ambient conditions and requirements given in Appendix C and Appendix H.

The Contractor ensures that leakage does not exceed 1.0% of full load for maximum pressure differential

across the damper at design conditions.

The Contractor specifies guarantee draft loss (resistance) performance with dampers in the full open position.

Poppet Dampers “Damper Stroke” (or with the other opening as stated by the Contractor). The openings of the

dampers are stated in the Contractor’s tender response.

1.2.1.3 FFP Compartment inlet Louver Dampers

The Contractor guarantees that the Fabric Filter Compartment Inlet Louver Dampers supplied, by the

Contractor, meets the following guarantees across the range of operation and ambient conditions given in

Appendix G:

Leakage: Louver-style dampers are of the tight shut-off design with mechanical interlocks.

Draft loss (resistance): The Contractor to specify guarantee performance with damper in the full open

position.

1.2.1.4 FFP Compartment Ventilation System

The Contractor guarantees the following across the range of operating conditions as given in Appendix M

and the attached site conditions in Appendix C.

The Contractor guarantees that the supplied Plant and Material provides the specified gas flow rate at the

specified discharge pressure across the entire range of ambient conditions.

The electrical power consumption, measured at the power input leads to all supplied Plant and Material and

averaged over a 24 hour period, is guaranteed by the Contractor at the design conditions specified with zero

tolerances. Fans are tested in accordance with ASME PTC 11.

The noise level of all supplied Plant and Material does not exceed 85 dB(A) measured at a distance of 1

meter horizontal from the Plant and 1.5 meter above floor level. In addition to sound power levels, sound

pressure levels (Lp) are provided in octave bands.




1.2.1.5 FFP Pulse Air Headers

The Contractor guarantees the air consumption required to operate one (1) pulse air header at a time when

the number of pulse valves (as specified in Appendix P) per air header is actuated simultaneously. Each

pulse valve i s capable of providing the minimum Scm (volume) per bag with 200 msec pulse duration

measured at the blowpipe outlet as specified in Appendix P.

The Contractor guarantee the noise level of the pulse air header (immersion valves and headers) does not

exceed 105 dB (A) when measured at a distance of 1.5 m from the valves or header.

1.2.1.6 FFP Valves

The Contractor supplies Plant and Material that meet the specified requirements over the stated range of

operating conditions as specified and required in Appendix C, Appendix V part 19 and as per valve lists 360-190,

360-1187 to 360-1194.

1.2.1.7 Filter Bag Cages

The Contractor guarantees the following:

The cages will not deform during assembly.

The cages can be disassembled and re-assembled as needed over the life of the cage without

deformation of the cage or loss of joint integrity.

The assembled coupling connections are firm and not work loose during the life of the cages.

The coupling connection / joint resist a minimum vertical load of 45 kg. A maximum load is

established at the time of the sample inspection.

Joints are disassembled without the use of tools.

1.2.2 Reuse of existing plant

The following has been identified for possible reuse:

Earthing straps connected to the existing mats; the reuse of such straps is subject to acceptance by

the Project Manager.

Cable racks; the reuse of cable racks is subject to acceptance by the Project Manager.

Reuse of existing structures as per the Employer’s design

o ESP support structure and foundations; these are modified as per the Employer’s design.

o ESP hoppers; these are modified as per the Employer’s design.

o Longitudinal walls of ESP casing; these are modified as per the Employer’s design. The

Contractor also submits an alternative solution for removing the longitudinal walls as per

Section 3.1.1.7.1.

The Contractor may reuse existing plant, subject to acceptance by the Project Manager. The Contractor

indicates the cost saving associated with the reuse of additional existing plant, any impact on the schedule

and includes a motivation supported with the relevant calculations or assessments.




1.2.3 Limits of Supply and Services (LOSS)

The interface documentation created by the Employer is used by the Contractor. These include the Tutuka

Power Station ESP to FFP Retrofit Project Limit of Supply & Services (LOSS): 360-619 and Tutuka Power

Station FFP Retrofit Project Terminal Point (TP) Register: 360-189. The Terminal Point Register and

Terminal Point Data sheets are populated by the Contractor and supplied to the Project Manager.

The following is a summary of the interfaces; these are read in conjunction with 360-619:

System Terminal point (inclusive to works)

Flue gas path

LOSS-06-07-01

LOSS-06-07-02

LOSS-EE-06-01

First expansion joint after the air heater outlet to the ID fan inlet.

Civil and Structural

LOSS-SS-AA-03

The existing ESP support structure and casing

Existing duct work

Existing ductwork support structures and foundations

Existing ground slab in current ESP region

Ground between ESP and ID fan

DHP (Fly ash handling

system)

LOSS-06-08-01

LOSS-06-08-02

LOSS-06-08-06

LOSS-06-08-07

LOSS-06-08-08

Hopper knife gate (by Others) of the existing dust hoppers.

Connections for installation of aeration pads (aeration pads by Others) in

each hopper.

Relocation of fuel oil piping to accommodate the construction of the DHP

Blower house.

Installation (by Others) of vent pipe from DHP system to FFP hopper.

DHP Vacuum Pipe from ash bunker to FFP inlet ducting.

Installation of FFP Hopper Blanking Plates.

FFP and DHP compressor house.

FFP and DHP compressor house earth mat installation.

Electrical Reticulation

LOSS-FFP-ERT-01

LOSS-FFP-LVS-01

LOSS-FFP-MVS-01

The cables from the 11kV Substation East Board A and 11kV Substation

South Board B for the FFP Compressed Air Plant reticulation.

The supply cables from the 11/0.4kV Precipitator Transformers A and B,

for the units 1 to 6 reticulation.

The cables from the 3.3kV FFP Cleaning Air Equipment Boards A and B.

380V Unit Diesel Generator Boards for units 1 - 6.

The supply cables from 400V Unit UPS system, for Units 1 to 6, to PA

Sequencer DBs.

The main supply cable for the Construction Workshop electrical




System Terminal point (inclusive to works)

installation.

The new Lighting and Small Power Distribution Boards on top of each

casings.

Control and

Instrumentation

LOSS-FFP-BLD-01

LOSS-FFP-BV-01

LOSS-FFP-CV-01

LOSS-FFP-FM-01

LOSS-FFP-LM-01

LOSS-FFP-MCC-01

LOSS-FFP-NLP-01

LOSS-FFP-PM-01

LOSS-FFP-PM-02

LOSS-FFP-PM-03

LOSS-FFP-PS-01

LOSS-FFP-TM-01

LOSS-FFP-TM-02

LOSS-FFP-CnI-01

LOSS-FFP-CnI-02

The Contractor supplies and installs instrumentation, instrument piping,

instrument and control cabling, conduits and terminates at localised

junction boxes/enclosures for Unit 1 - 3. The Contractor interfaces with

Others in Unit 1 - 3 to realise a complete functional, operational FFP

control system.

The Contractor supplies and installs instrumentation, instrument piping,

instrument and control cabling, conduits and terminates at localised

junction boxes/enclosures for Unit 4-6 and common plant. The

Contractor installs trunk cabling and cable trays/racking and terminates

at the junction boxes/enclosures and the DCS/Marshalling control

cubicles in Unit 4 – 6 (for FFP) and common plant DCS (for the cleaning

air equipment plant systems).

ID Fan Permanent hoists for maintenance activities on ID Fans.

Low Pressure

Services

LOSS-06-08-04

LOSS-06-08-03

LOSS-SS-AA-03

LOSS-06-08-05

The downstream flange of the valve (by Others) on the demineralised

water supply piping to the FFP and DHP compressor house.

The downstream flange of the valve (by Others) on the potable water

supply piping to the FFP and DHP compressor house.

Piping on pipe supports provided by Others at the interface points for the

FFP pulse and instrument air piping which are at the inlet to each FFP

pulse air receiver and the instrument air tap off points to each unit as

indicated in the drawings 0.61/97205 Sheets 1 to 40.

The downstream flange of the valve (by Others) on cooling tower blow

down piping to the dirty water drains.

1.2.4 Interface with Others

The Contractor interfaces with Others on Site and shares the Working Areas with them. The Contractor

provides the Project Manager with requirements such as consumer power requirements, termination

interface requirements and design philosophies in order to complete the design and installation of the works.




The Contractor is responsible for all system interfaces which forms part of the works. The Project Manager

will provide the relevant information defining the system interfaces. The Contractor caters for all identified

interfaces and coordinates work with the ID fan replacement, MV switchgear replacement, DHP Upgrade and

C&I Refurbishment scopes of work and Others.

The Contractor is required to interface as described below. To facilitate interfacing with Others, the

Contractor provides a proposed construction methodology, duration and a mark-up of the area required for

construction activities to the Project Manager. In all instances, the Contractor is responsible to integrate

technically, work requirements and scheduling with the following project interface details and requirements

discussed below and detailed in the corresponding sections:

The Contractor interfaces with the construction of the ID fan upgrade. The Contractor is aware

of the ID fan contractor’s requirements for construction; this information will be provided after

Contract Award.

The Contractor interfaces with the construction of the Dust Handling Plant upgrade underneath

and in the FFP hoppers.

The DHP contractor will be installing aeration pads in the FFP hopper. The Contractor ensures

that the DHP contractor has access to the FFP hoppers when required to perform work and

installs the connections for the aeration pads.

The Contractor installs hopper blanking plates at the bottom of the FFP hoppers to allow the

DHP contractor to perform safe work on the DHP system. The Contractor ensures that the DHP

contractor has access to the FFP hoppers when required to perform work.

The DHP contractor interfaces at the FFP hopper knife gate. The Contractor interfaces with the

DHP contractor to coordinate the work and communicate connection details.

The Contractor interfaces with the DHP contractor w.r.t the installation of a venting pipe from

the DHP system to the inside of the FFP hopper. The Contractor ensures that the DHP

contractor has access to the FFP hoppers when required to perform work and provides any

information required to install and design the vent piping.

The Contractor interfaces with the DHP contractor in the FFP and DHP compressor house. The

DHP contractor constructs the FFP and DHP compressor house and the Contractor installs the

Cleaning Air System Plant and Materials. The Contractor interfaces with the DHP contractor for

access and requirements.

The Contractor interfaces with the DHP contractor for the demineralised and potable water

supply to the FFP and DHP compressor house.




The Contractor is aware of the DHP contractor requirements for construction of a unitised DHP

Blower House; this information will be provided to the Contractor.

The Contractor interfaces removes and installs the DHP vacuum pipe from the ash bunker to

the FFP inlet. The Contractor interfaces with the DHP contractor w.r.t the timing of the removal

and installation.

The Contractor removes the bucket elevators and structural steel support for the bucket

elevators from the roof of the bunker. The Contractor interfaces with the DHP contractor w.r.t

the timing of these activities.

The Site has constricted access. The Project Manager will convene an interface meeting with

all the role players that is affected in the area and determine the access for each contractor.

These interfaces affecting the Contractor (i.e. access to and from the Contractor) will then be

scheduled by the Contractor in his programme

Information with regard to the FFP outlet flue transition support structure is provided to the

Contractor.

The Contractor interfaces with the Employer with regard to routine maintenance and

refurbishment performed on low pressure services and plant systems.

FFP LV Switchgear IED’s is free-issued to the Contractor by Others. The Contractor is required

to liaise with the IED OEM with regards to the functions of the IED in order to complete the

manufacturing/detail design for the incomers and bus sections on the 400V FFP Boards A and

B for units 1 to 6, as well as the 400V FFP Compressor House Boards A and B. The Contractor

installs the IED as required, under the supervision of an OEM representative.

The Contractor liaises with the Project Manager to obtain the final ID fan auxiliary load

information, before the detail designs of the 400V FFP Boards A and B, for Units 1 to 6, are

finalized.

The Contractor liaises with the Project Manager to obtain the final size of the 11/3.3kV Cleaning

Air Equipment Transformers, before commencing with the manufacturing/detail designs for

these.

The Contractor liaises with the Project Manager to obtain the final size of the 11kV and 3.3kV

cables of the 11/3.3kV Cleaning Air Equipment Transformers, before placing the order for

these.

The Contractor notifies the Project Manager of the final sizes of the 3.3kV FFP Compressors as

soon as these have been selected.




The Contractor interfaces with Others in Unit 1-3 to realise a fully functional, operating system

since there will be a new DCS installed by the Others under C&I Unit 1-3 control system

replacement project.

The Contractor is responsible for the removal of bucket elevators, the structural steel support

structures, the bucket elevator hopper and chute to the ash bunker from the ash bunker.

1.3 Interpretation and terminology

The following abbreviations are used in this Works Information:

Acronym DefinitionABD Availability Block Diagram

AIA Approved Inspection Authority

AKZ Anlagenkennzeichnungssytem

ASME American Society of Mechanical Engineers

ASTM American Society for Testing Materials

BFP Boiler Feed Pump

BHP Brake Horse Power

BMS Boiler Management System

BPS Boiler Protection System

C&I Control and Instrumentation

CAR Corrective Action Report

CEC Compensation Events Committee

CM Configuration Management

COC Certificate Of Compliance

CO2 Carbon Dioxide

CPI Cost Performance Index

CPM Critical Path Method

CQP Contractor Quality Plan

CT Current Transformer

CV Curriculum Vitae

CW Cooling Water

DC Direct Current

DCP Dry Chemical Powder

DCS Distributed Control System

DEA Design Erection Arrangement

DHP Dust Handling Plant

ESP Electrostatic Precipitator

FAT Factory Acceptance Test

FFP Fabric Filter Plant




Acronym DefinitionGA General Arrangement

GO General Outage

GPS Global Positioning System

HMI Human Machine Interface

HP High-Pressure

HPLV High Pressure Low Volume

HV High Voltage

I/O Input/Output

ID Induced Draught

IED Intelligent Electronic Device

IP Intermediate-Pressure / Intellectual Property

ITP Inspection and Test Plans

kP Kilopascal

kPa Kilopascal Absolute Pressure

kPg Kilopascal Gage Pressure

kV Kilo Volt

kW Kilo Watt

LAR Limited Access Registers

LH Left-hand

LOSS Limit Of Supply and Services

LOTO Lock-Out/Tag-Out

LP Low-Pressure

LV Low Voltage

mA Milli Ampere

MCC Motor Control Centre

MCR Maximum Continuous Rating

MDL Master Document List

MFT Master Fuel Trip

MTTR Mean Time to Repair

MV Medium Voltage

NCR Non-Conformance Report

NDT Non-destructive Testing

NRV Non Return Valve

OAT Operation Acceptance Test

O&M Operating and Maintenance

O2 Oxygen

OBL Outside battery limits

OEM Original Equipment Manufacturer

OHS Act Occupational Health and Safety Act




Acronym DefinitionOPCR Outside Plant Control Room

P&ID Piping and Instrumentation Diagram

PD Plant Discharge

CPA Contract Price adjustment

PFFR Pulverised Fuel Firing Regulation

PIS Plant Information System

PPS Polyphenylene Sulphide

Pr.Eng Professional Engineer

PSR Plant Safety Regulations

PTFE Polytetrafluoroethylene

QA Quality Assurance

QA/QC Quality Assurance/Quality Control

QCP Quality Control Plan

QMS Quality Management System

RAM Reliability Availability and Maintainability

RH Right-hand

RVC Radial Vane Control

SAS Substation Automation System

SAT Site Acceptance Test

VDSS Vendor Document Submittal Schedule

XLPE Cross-Linked Polyethylene

FFP/DHP Compressor House C&I

Equipment room

This room houses C&I equipment such as remote I/O panels and is

still referred to as a PLC room by other drawings and documents. It

should be noted that this room will not contain a PLC as it is

envisaged that each compressor/dryer will have its own local

controller to be interfaced to the DCS via remote I/O panels.

2 Management and start up

2.1 Management meetings

Meetings are held monthly between the Project Manager and the Contractor and any person instructed by

the Project Manager to attend. The Contractor is represented at each meeting by the duly authorised

member of the staff. Additional ad hoc meetings may also be called to address urgent issues.

The Project Manager, as and when necessary, requires the Contractor to attend meetings with Others

performing work onsite and during the same outage. This requirement does not constitute a compensation

event.

The venue for these meetings is as determined by the Project Manager. The Project Manager writes the

minutes of meetings and circulates to attendees within five working days.




Any action of the Project Manager and the Contractor implied in the minutes of meetings is confirmed by a

separate formal communication between the Project Manager and the Contractor.

The Contractor reports the overall progress and as a minimum requirement, the following is addressed:

Contractor’s current activity progress and planned finish dates

Contractor’s planned start and finish dates for the works

Contractor and Project Manager’s programme agenda, current and projected manpower by

class

Health, safety and quality issues

The progress of any relevant activities

Discussion on any technical and commercial issues

Problem areas or concerns

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

Table 1: Meetings Schedule

Title and purpose Approximate time &

interval

Location Attendance by:

Risk register and

compensation events

Weekly Venue determined By

the Project Manager

Relevant appointed

members of a Risk or and

Compensation event

committee

Overall contract

progress and feedback

(from contract date to

execution

commencement )

Monthly/ During

execution meeting are

daily in the morning

Venue determined By

the Project Manager

Employer, Contractor,

Supervisor, and Others as

determined by the Project

Manager

Overall contract

progress and feedback

during execution


the Project Manager




Manager

Planning Meetings

(including integration

meetings with Others)


the Project Manager


Supervisor, Planners and

Others as determined by




Title and purpose Approximate time &

interval

Location Attendance by:

the Project Manager

Technical meetings As and when required Venue determined By

both parties

Project Manager and

Contracter as well as any

other attendees required.

Interface meeting As and When Required Venue determined By

both parties

Contractor’s others,

Project Manager,

Supervisor.

Safety Meetings Monthly Venue determined By

the Project Manager


Supervisor Safety Officers

and Others as determined

by the Project Manager

Outage meetings

(including integration

meetings with Others)

Daily During outage Venue determined By

the Project Manager




Manager

Meetings of a specialist nature may be convened as specified elsewhere in this Works Information or if not

so specified by persons and at times and locations to suit, the nature and the progress of the works.

Records of these meetings must be submitted to the Project Manager by the person convening the meeting

within five days of the meeting.

All meetings are recorded using minutes or a register prepared and circulated by the person who convened

the meeting. Such minutes or register must not be used for the purpose of confirming actions or instructions

under the contract as these must be done separately by the person identified in the conditions of contract to

carry out such actions or instructions.

Where the Contractor requires additional information to design and install certain areas of the Plant or

Employers design, the Contractor confirms the details with the Project Manager a week before continuing

with the works. These clarifications and requirements are discussed at the weekly progress meetings.




2.2 Documentation control

2.2.1 General

The Contractor complies with the requirements of the Project Documentation Deliverable Requirement

specification, 240-65459834 and VGB-R 171e “Guideline for the supply of technical documentation for fossil-

fired and regenerative power stations” which forms part of these requirements.

In addition, the Contractor’s document system complies with ISO 9001 requirements and is comprehensive

in management and control of the documentation for each of the units based on a master document. The

documentation requirements cover the various engineering stages, from the design stage through

fabrication, installation, testing, commissioning, operating, maintenance and training stage of the project.

The Contractor provides the configuration management(CM) plan, at tender, that will be implemented in line

with the ISO 10007 Guidelines for Configuration Management. The CM plan should reflect where

Configuration Management is in the project Structure, a technical document and record management

procedure as well as the Change management procedure the Contractor will be using.

The Contractor is responsible for the compilation and the supply of the documentation during the various

project stages and to provide the documentation programme to link with the milestone dates. Documentation

and drawings are programmed for delivery to meet the milestone dates and in accordance with the agreed

VDSS.

2.2.2 Document Control and Management

The documentation requirements cover the various engineering stages, from the design stage through

fabrication, installation, testing and commissioning and most importantly for the operating, maintenance and

training stage of the project.

The Contractor is responsible for the compilation and the supply of the documentation during the various

project stages and to provide the documentation programme to link with the milestone dates. Documentation

and drawings are programmed for delivery to meet the milestone dates and in accordance with the agreed

VDSS, attached in Appendix B.

2.2.3 Documentation Pre-submission

The Contractor is responsible for the submission of the Vendor Documentation Submittal Schedule (VDSS)

which lists all documentation deliverables for all work to be done by the Contractor as per the Works

Information. The Employer in the Works Information will list minimum documentation deliverables which is

utilised by the Contractor to develop the VDSS. The VDSS shall link with the completion of work as per the

activities in the programme and will then be submitted by the Contractor to the Project Manager for review

and acceptance. Should the programme be revised, the updated VDSS must be submitted as per the revised

programme.




2.2.4 Process for Documentation Submission

The layout and format of all documentation deliverables must be in accordance with the Gx Projects

Documentation Deliverable Requirements Specification (240-65459834) and Engineering Drawing Standard

– Common Requirements (240-86973501). All documentation submitted must be accompanied by the

completed transmittal with the following fields as a minimum: (Refer to 240-71448626 - Project Plant Specific

Technical Documentation Transmittal Template.)

Name of the Package and system

Name of Contractor

Transmittal Number

Contractor Details

Date of Submission

Description of Document

Document Number

Document revision

Document type

Document media type

Number of copies

Purpose of submission

Document PBS

Signed by and date

For review purpose, all documentation is submitted, by the Contractor, in native electronic format and PDF

format as described in Gx Projects Documentation Deliverable Requirements Specification (240-65459834),

and all drawings as prescribed in the Engineering Drawing Standard – Common Requirements (240-

86973501), Final documentation is submitted in both electronic and hard copies to the Project

Documentation Centre.

The Contractor is to supply four (4) hard copies and electronic copies of all drawings, specifications,

operating manuals and instructions that are required to maintain and operate the assembly prior to

commissioning of the plant.

Submission of documentation deliverables must be in accordance to the task completion or no later than 14

calendar days after completion of task as stipulated in the agreed VDSS / Master List.

The Contractor submits all documentation to the Project Manager as well as the Project’s Documentation

Centre in the following media:

Electronic copies shall be submitted to Eskom Documentation Centre through the project’s email

address ([email protected]). The email subject as a minimum has the following:

(Station_Project Name_Discipline_Subject). The project’s Document Controller is copied on

submission. Electronic copies that are too large for email is delivered on CD/DVD, large file transfer

protocol and/or hard drives to the Project Documentation Centre.




All the submission by the contractor must be accompanied by the Transmittal note.

By acknowledging receipt, the Contractor signs and sends the transmittal note back to the Employer within 2 working days.

2.2.5 Documentation Recording

The Employer provides a list of documentation to be developed and submitted by the Contractor, in

Appendix.

The Contractor develops; documents and maintains the Master Document List (MDL) with all the metadata

which will be sent to the Employer as per the MDL template provided by the Employer in Appendix Q.

The Contractor submits the MDL to the Employer in the monthly (10th of every month) basis for tracking

purposes irrespective of whether there are updates or not. The MDL includes list of drawings and documents

and contains the following minimum information for each document:

Date of submission

Transmittal number

Transmittal title

Document description

Document number (both Contractor and Employer)

Document Type

Revision number

Document Approval Status

Document Authorisation Status (i.e. Accepted With Comments, Not Accepted with Comments,

Accepted)

Transmittal Reason for Issue

In addition, the Contractor adheres to the following standards:

Documentation Management Review and Handover Procedure for Gx Coal Projects (240-

66920003).

Project Documentation Deliverable Requirement Specification (240-65459834).

Technical Documentation Classification and Designation Standard (240-54179170).

Project / Plant Specific Technical Documents and Records Management Procedure (240-53114186).

SmartPlant for Owner Operators (SPO) Documentation Metadata Standard (240-58552870)

SmartPlant Data Take-On Guideline (240-96659378)

2.2.6 Documentation Review and Turn-around

All document review periods are as the reply period in the Contract data. Design review, as per design

review procedure (240-53113685), response period will be 1 month.

All correspondences are recorded in a formal letter with the letter head and must have correspondence

number as agreed with the Project Manager A register of all correspondences is kept by both the Project




Manager and Contractor. The Contractor submits a report of the updated register to the Project Manager on

a monthly basis. The correspondence register must contain the following information as a minimum:

Correspondence number

Date of issue

Description of the correspondence

Reference numbers to previous correspondences

Package specific email address need to be created and referenced to

2.2.7 Email Subject

The Contractor submits all documentation to the Project Manager as well as the Project’s Documentation

Centre in the following media:

Electronic copies shall be submitted to Eskom Documentation Centre through generic email address

([email protected]). The email subject shall as a minimum have the following:

(Station_Project Name_Discipline_Subject). Electronic copies that are too large for email will be

delivered on CD/DVD, large file transfer protocol and/or hard drives to the Project Documentation

Centre. A notification email, with the transmittal note attached, shall be sent to the project generic

email address. The Representative will be copied on the email as well.

Hard copies shall be submitted to the Eskom Representative accompanied by the Transmittal Note.

By acknowledging receipt, the Contractor signs and sends the transmittal note back to the Employer within 2 working days.

2.2.8 Data

The Contractor supplies descriptive data including but not limited to equipment list, price schedules, and

speciality item lists in Ms Excel compatible to the Employer’s latest version. Compliance to this requirement

does not constitute compensation event. The aforementioned lists contain the following fields for each item

as a minimum:

functional location

tag ID (consistent with Employers specifications)

description

associated drawing and document names (that contain references to this item)

approval status

2.2.9 Plant Coding and Labelling

All documents and drawings have been coded by the Employer. The Employer is responsible for the coding

of the Tutuka FFP. During construction it may appear that some equipment has not been coded.

The Contractor informs the Project Manager of such equipment and submits relevant documents/drawings to

the Project Manager to allocate codes. After allocating codes the Project Manager sends the corrected

documentation to the Contractor who will incorporate the new codes.


mailto:[email protected]



Tutuka AKZ Coding Manual (15ENG MN-675) is used for plant coding.

The Contractor ensures that the codes are applied in a uniform and consistent way and that all codes

allocated by the Employer are unique.The Contractor sends the documents and drawings to the Project

Manager for acceptance.

The Contractor provides the Project Manager with the following:

Outline drawings or diagrams, equipment lists

In respect of items procured by the Contractor from another manufacturer or vendor, the Contractor

provides the name of the actual manufacturer and his coded drawing or reference numbers and

relevant technical data for identification purposes.

2.2.9.1 Plant Labelling

It is the responsibility of the Contractor to manufacture and install labels. Labels are manufactured and

installed according to the Tutuka AKZ Plant Labelling Guideline (240-62937990, Rev 1).

Labelling includes the relevant AKZ code with English descriptions. The Contractor submits a Label

Schedule/List spread sheet to the Project Manager for verification and acceptance, 60 days before

commencement of manufacturing. The Label schedule includes the label information such as the AKZ code,

full label description, positioning and designation.

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 are submitted to the Project Manager for acceptance.

2.3 Health and safety risk management

The Contractor at all times complies with applicable statutes and Eskom’s Business requirements

which include but not limited to the following: Occupational Health and Safety Act Number 85 of

1993 and its Regulations, Eskom SHEQ Policy, Standards, Procedures, Guidelines and

Specifications.

The Contractor ensures safety awareness at all times through continuous training.

The Contractor is responsible for the supervision of his employees, agents and sub-contractors at all

times, and takes full responsibility and accountability in ensuring that they are competent, compliant

and aware of the legal requirements and other applicable requirements, and also executes the works

in accordance with Construction Regulation, 2014 or as amended from time to time.

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

Policy, standard and procedure are recorded in writing and that all its appointees and/or agents fully

understand their responsibilities and are trained and competent to execute their duties.




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

contract:

o Conduct health and safety audits by a competent person regarding all aspects of compliance

with the SHEQ requirements, at any off-Site place of work, or the Site establishment of the

Contractor.

o Refuse any employee, sub-contractor or agent of the Contractor access to the premises if

such person has been found to commit an unsafe act or if any work is found not to be

compliant or authorized.

o Issue the Contractor with a STOP WORK ORDER should the Employer become aware of

any unsafe working procedure or condition, or any non-compliance.

The Contractor immediately reports all incidents, as well as any threat to safety and health, of which

he becomes aware at the Site, to the Project Manager.

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

in terms of the Occupational Health and Safety Act no 85 of 1993 in respect of any acts or omissions

of the Contractor, and the Contractor’s employees, agents or sub-contractors, to the extent permitted

by the Occupational Health and Safety Act no 85 of 1993.

The Contractor provides a health and safety plan based on the Employer’s Safety, Health and

Environmental Specification, GCD/TUT/SHE06.

All persons entering the Site undergo the Employer’s safety induction course.

The designer of the works is mandated to comply with section 6 of the construction regulations.

In the event of any one of the following incidents occurring, an investigation shall be initiated and the

Contractor status will be subjected to reconsideration by Supplier Status Committee:

o a supplier has one or more work-related fatalities within a financial year or the period of the project for contracts of less than one year;

o a supplier experiences three lost-time incidents in the same financial year;o a supplier has three major SHE non-conformances raised in the same financial year;o a supplier has had two or more contraventions of environmental legislation, including

noncompliance with a condition contained in an environmental approval;o the contractor has been issued with a compliance notice issued by a government

department, for example, the Department of Labour, Department of Environmental Affairs, Department of Water Affairs, etc.;

o a violation of any of the Eskom Life-saving Rules occurs;o Fraudulent SHE-related documents are submitted by a supplier.

2.3.1 Safety of Worker

The Contractor ensures the safety of all persons working on the Site. Any hot work, including welding, is

applied for in accordance with the permit to work system. No hot work is allowed on Site unless a hot work

permit is granted by the Employer in writing.

2.3.2 Fire Protection

The Contractor ensures that adequate firefighting apparatus is provided in all applicable areas where the

works are being carried out and that his employees are trained in the use of this apparatus.

Fire blankets are fitted over scaffolding planks and platforms whenever hot work is being carried out.




The Contractor takes precautions to prevent any occurrence of fires or explosions while carrying out any

work near flammable gas and liquid systems. Any tampering with the Employer’s fire equipment is strictly

forbidden. All exit doors, fire escape routes, walkways, stairways, stair landings and access to electrical

distribution boards are kept free of obstruction, and are not used for work or storage at any time. Firefighting

equipment remains accessible at all times.

In case of a fire, the Contractor immediately reports the location and extent of the fire to the Electrical

Operating Desk using the Emergency Number 5400. The Contractor takes the necessary action to safeguard

the area to prevent injury and spreading of the fire.

2.3.3 First Aid

The Contractor provides First Aid services to his employees and sub-contractors. In the case of severe or

serious injury, to his employees and sub-contractors the Employer’s Medical Centre and facilities are made

available and accessible to such persons.

2.3.4 Housekeeping

It is the Contractor’s responsibility to ensure that his working areas within the Site are cleaned daily. All

electrical cables and hoses are routed so as not to cross unprotected over floors and walkways. All

equipment is packed neatly without interference to access. All excess scaffolding material is removed from

Site after the scaffolding has been erected. The Contractor is responsible for the removal of any scrap

material to the designated scrap area on a daily basis.

2.3.5 Barricading

Access to danger zones is restricted using handrail type guards at least 1.2 meters high and able to block

access to the danger zone. Symbolic safety signs depicting ‘Danger’ and ‘No entry’ are attached to the

guards. This includes access during the taking of X-rays.

2.3.6 Radiographic Examinations

When radiographic tests are carried out in the plant by Others, the danger area is evacuated with the

exception only of authorized radiographic workers, and thereafter barricaded. To ensure that employees and

contract staff working in Eskom premises are not exposed to more radiation than is reasonable level,

compliance is with the Tutuka Power Station procedure ‘Requirements and Rules for Radiation Protection

and Safety of Radiation Sources’, reference number 15MNT MSS PC-1267.

2.3.7 Permit to Work System

The Contractor allocates personnel to be trained and authorised as Responsible Persons according to

Employer’s Plant Safety Regulations (36-681). The Contractor ensures that an adequate number of its

employees are trained and authorised as Responsible Persons and Authorised Supervisors prior to the

outage date. The Contractor ensures that Responsible Persons and Authorised Supervisors are available on

Site at all times.




2.4 Environmental constraints and management

The Contractor ensures that all goods, services or works supplied in terms of the contract comply with all

applicable environmental legislation including but not limited to the (National Environmental Management

Act, 1998 [Act No 107 of 1998]).The Contractor is responsible for keeping the work area and Site clean of

any environmental waste.

All waste introduced and/or produced on the Employer’s premises by the Contractor for this contract, is

handled in accordance with the minimum requirements for the Handling and Disposal of Hazardous Waste in

terms of Government Legislation as proclaimed by the Department of Water Affairs and Forestry and

Employer’s environmental requirements (Waste Management Procedure; 32-245 and Management of Waste

at Tutuka PS; PS/244/001).

All environmental incidents are reported to the Project manager within 24 hours of such occurrence. All

environmental incidents occurring on Site (or on any other places, if any, as may be specified under the

Contract as forming part of the Site) are recorded, detailing how each incident was dealt with in an

Environmental Incident register.

2.5 Quality assurance requirements

2.5.1 General

The Contractor complies with the Employer’s quality and technical requirements including those

listed in the Employers Supplier Contract Quality Requirements Specification document, QM58-

240-105658000.

The Contractor submits a Quality Management System (QMS) as a returnable schedule and uses

it for all phases of the Project. The QMS complies with the requirements of ISO 9001 standard.

The Contractor provides evidence of a fully implemented QMS. The Employer may at his sole

discretion carry out an audit on the Contractor, the Contractor’s suppliers and Subcontractors.

2.5.2 Quality Management documents requirements

The Contractor submits the following documents, within 30 days of the Contract Date, to the Employer for

review and acceptance and prior to the commencement of work.

The Contractor supplies the Employer with a Contract Quality Plan (CQP) which details the Contractor’s

organisation, quality assurance and quality control procedures within that organisation specific to this project.

The CQP is aligned to, and reference ISO 10005:2005 QMS, guidelines for quality plans and is in

compliance with the guideline in QM58-240-105658000. The CQP makes reference to the Contractor’s QMS

Procedures to be used in this Contract:

The Contractor’s QMS compliance with the requirements of ISO 9001

Contractor’s quality manual

Contractor’s quality procedures

Contractor’s quality forms and work instructions




Contractor’s quality system documents referenced in this Works Information

The Contractor supplies the Supervisor with a QCP or ITP for review and acceptance.

The Contractor supplies the Project Manager with a detailed contract organogram showing the quality

personnel to be used in the Contract. The Contractor provides CVs of the quality management employees

responsible for quality on Site.

Contractor Quality Management employee’s responsibilities include, but are not limited to, the following:

Implementation of the QMS

Administration of QA/QC systems

Verification of approval status of Subcontractor’s QCP and procedures

On-and -offsite inspections

Co-ordination, inspection and verification of the Employer’s intervention points

Review of Contractor testing and inspection documents (procedures, test results)

The Contractor supplies QCPs and/or ITPs, for all Plant and Material, as required in the VDSS attached to

Appendix B.

2.5.3 Reporting on quality performance

The Contractor submits as a minimum the following documents, as required by the Project Manager, which

requirement does not constitute a compensation event, during the execution of the works;

Updated QCP register, on a monthly basis

Inspection notifications, accompanied by applicable inspection report 48 hours before the

inspections

Non-conformance and Defects registers and reports on a monthly basis

Updated Site and off site inspection schedules on a monthly basis

Inspection and or FAT dates on a weekly basis

Inspections completed/outstanding on a monthly basis

Inspection and test reports on a monthly basis

Monthly contract quality progress report

Data books for the completed work before commissioning can commence

2.5.4 Quality Responsibility

The Contractor is accountable for the quality of the output and liable for any failures.

The Contractor is responsible for defining the level of intervention of QA/QC or inspections.

These are in line with the Employer’s requirements.

The Contractor is responsible for defining the level of intervention of QA/QC or inspections to be

imposed on his sub-Contractor, suppliers and sub-suppliers and must ensure that these are in

line with the Employer’s requirements.

The intervention requirements take into consideration the criticality of the Plant and Material.




The intervention points include all witness, hold, verification and review points required by the

Employer. The Contractor’s failure to allow the intervention points constitutes a non-

conformance. (Refer to Section below).

2.5.5 Inspections

The Contractor is responsible for the inspection of all the work that is performed and the

Supervisor only verifies that the work is conducted as per the contract.

The Contractor conducts all inspections in accordance with the accepted QCP / ITP.

The Contractor drafts a QCP or ITP which shows each activity from the Works Information and

submits to the Supervisor for acceptance.

The Contractor provides suitably qualified personnel to conduct on-and-offsite inspections

The Contractor ensures that all work are inspected and approved before the Supervisor is invited

for verification.

The Contractor provides a minimum of 24 hour notice for local inspections and 21 working days’

notice for foreign inspections. The notice contains copies of the Contractor’s inspection reports.

2.5.6 Non Conformances and Defects

Where NCR’s and Defect notifications are issued, the Contractor acknowledges receipt within 48 hours and

proposes corrective and preventive actions to the Supervisor as per the QM58-240-105658000. The Project

Manager will implement an R2000.00 (two thousand Rand) per day penalty in the event that a Non

Compliance Report (‘NCR”) is not closed within the specified days of being issued. The corrective and

preventive actions include the implementation and completion dates. Progress on all NCR’s and Defect

notifications issued to the Contractor is reported to the Supervisor on weekly basis.

The Contractor’s quality manager keeps a register of all NCR’s and Defect notifications

issued

Deviations from the Contract are treated as a non-conformance.

Records of NCRs and Defect notifications are kept and form part of the data book records.

To ensure reduction of non-conformances, the Employer will implement a penalty to the value of R10 000.00

for every five (5) NCRs issued during the contract period.

During the contract execution phase, the Contractor is monitored by the Employer for performance on quality

related aspects. The monitoring is in the form of audits and assessments.




2.5.7 Quality Reporting

The Contractor submits a monthly quality report, on the last working day of the month. The report includes

but is not limited to the following:

A register of NCRs and defects

Updated QCP / ITP register

QA monthly report summary

Planned and completed local and foreign inspection dates

Completed and outstanding Inspections

Audit findings report

2.5.8 Preservation, shipping and transportation

The Contractor ensures that all Plant and Material are preserved in an appropriate manner as described in

the Works Information. The Contractor submits the preservation, shipping and transportation procedures to

the Project Manager for review and acceptance. The Project Manager may, choose to witness the

packaging, loading and offloading of the Plant and Materials.

The Contractor ensures that all storage requirements for Plant and Material as well as the existing equipment

are properly implemented to preserve the products against adverse conditions, deterioration, damages, etc.

Storage and preservation procedures for the different products are submitted to the Project Manager for

acceptance. The Project Manager may request to inspect the stored products at any given point during the

storage period.

For specific requirements on shipping and tagging refer to Section 4.3.3.1.

2.6 Programming constraints

The Employer provides the Key Dates as set out in clause 11.2.9 of the Contract Data of the Employer, the

access dates in clause 30.1 of the Contract Data by the Employer; the interface points identified by the

Contractor in the Contractor’s Works Information and requirements set out in the Works Information.

The Contractor submits, as part of his tender response, a Level 3 programme which contains the following as

a minimum, and the information as included in Section 5.1.1.4:

The Key Dates

The access dates from clause 30.1 of the Contract Data by the Employer;

The detail on how the Contractor intends to achieve the Key Dates and the access dates;

Duration of long lead item

Total manufacturing and execution durations

The date of Site establishment;

Show all the critical paths;

The Contractor ensures that his programme contains sufficient float in order for the Contractor to

add interface and alignment with the Employer and Others;




Other factors, information, methodologies, detail and dates which the Contractor believes are

necessary for achievement of the interface with others; Key Dates, Completion Dates and access

dates.

The Contractor submits a detailed programme after Contract award in accordance with time period provided

in clause 32.2. This revised programme must contain the following:

All information required as [stated above];

the services and work (programs) of all his Subcontractors and suppliers;

the design schedule;

the construction schedule;

the planning schedule;

the construction and manufacturing schedule;

the commissioning schedule;

The Contractor submits an updated programme every 2 weeks during design and manufacturing, and twice a

week during execution. The updated programme is not a revised programme submitted in terms of clause

32 of the Contract.

The level of detail for each is set out below.

The Contractor submits a single programme that incorporates the services and work (programs) of all his

Subcontractors and suppliers. The Accepted Programme must also clearly indicate interfaces between the

Contractor, the Employer, Others and his Subcontractors.

The Contractor must ensure that the Key Dates and interfaces with the Employer and Others are

incorporated into the Accepted Programme. To improve integration and interfaces with others and the

Employer, the Contractor participates in the integration meetings with the Employer, Cabling contractor, C&I

contractor and Others as required by the Project Manager. The information obtained from these integration

meetings are incorporated into the revised programmes submitted to the Project Manager. The Contractor

ensures that all dates, including Key Dates, between the Contractor, the Employer and Others are aligned in

the revised programme.

The Contractor’s obligation to meet the Key Dates and Completion Date is not altered by the Contractor’s

obligation to ensure that the Contractor’s programme shows and aligns with the interface requirements set

out in the Works Information.

Primavera Project Planner (version 6) has been adopted by the Employer for all planning, progress

monitoring and reporting on the project. The Contractor applies this programme for the planning and control

of the works in line with the accepted WBS. The Project Manager does not accept any programmes,

progress reports or other required planning data and information in PDF or any other form except Primavera

Project Planner (version 6).




The Employer has a Master Programme which incorporates the Contractor’s and Other’s programmes. The

Contractor submits updated electronic progress reports, as required by the Project Manager. The updated

progress report shows the logic and all filters and layouts used in the programme.

2.6.1 Planning Methodology and Programme Levels

All planning is done based on the Critical Path Method (CPM). The Contractor’s planning methodology

incorporates the compatibility, alignment and interface with others on the Project. This is clearly visible to the

Project Manager. The Accepted Programme clearly shows the actual critical path.

The following levels of programme are to be used for dynamic integrated project control:

Management level programme (Level 1)

Project level programme (Level 2)

Control level programme (Level 3)

Discipline specialty programme (Level 4)

2.6.1.1 Management Level Programme (Level 1)

The management level programme is used to establish work goals and overall time frames for the works. It

is a statement of project objectives recorded in graphic form. The management level programme defines:

Established goals or major milestone Key Dates; The duration of major operations and their relationship to one another;

Identified long lead material items;

Responsibility assignments for accomplishing project objectives.

2.6.1.2 Project Level Programme (Level 2)

A "rolled up" programme from the control level programme is produced. It will be separated by unit, plant

area and by activity.

2.6.1.3 Control Level Programme (Level 3)

The project level programme is prepared representing the significant work activities and deliverables

associated with the works. The end product is a time scaled bar-chart schedule developed through use of a

logic network.

This programme is separated by unit, by plant area, by phase and by WBS. The work within each plant area

is broken down by engineering discipline, procurement of tagged equipment, Construction by Contractor, and

commissioning and start-up. The control level programme is resource-loaded. It forms the basis for progress

measurement, progress curves and histograms for each discipline within a plant area.

2.6.1.4 Discipline Specialty Level Programme (Level 4)

The discipline specialty level programme is developed and maintained by the Contractor and generated for

tracking and control of various activities and deliverables for all phases of the project. This programme is




formatted as a spread sheet or database report utilizing the WBS structure. The programme represents the

day-to-day activities which are work unit based and become summarized in the level 3 activities.

The Contractor provides resource information in a resource histogram reflecting the manpower, plant,

material and equipment. Staffing histograms are required to be submitted based on “equivalent personnel”.

Staffing histograms are updated with actual data for each reporting period and re-forecasted as required

should significant deviations occur. The Contractor submits a 7(seven) day working program indicating all the

number of shifts.

2.6.2 Planning Schedules

Long lead manufacturing items and the dates for placing the main subcontracts is identified. Key contract,

program and interface events are identified in the contract program, including dates for access data and

release of terminal points that involve the Employer or Others. The Contractor submits a manufacturing and

procurement schedule as per Section 2.6.2.2 of this Works Information and ensures that it aligns with

planning, design and construction schedules. The Contractor ensures that its program fully aligns Others

and all interfaces are fully reflected. Refer to Section 1.2.4 and Appendix Z.

The program makes provision for site related preparation such as safety induction, and medical assessments

for the entire Contractor’s staff that will be working on site.

2.6.2.1 Design Schedule

The Employer provides the Contractor with a Master Document List (MDL) template as discussed in Section

2.2. The Contractor expands on the MDL and includes the submission dates of various revisions for

submission of the Contractor’s Design Documents using the Key Date for design freeze as a yardstick. The

initial design schedule is a returnable schedule.

The schedule also illustrates the sequence of work for the Project, including sequencing and alignment with

design of Others, and the dates for submission of drawings, studies and reports.

2.6.2.2 Procurement and Manufacturing Schedule

The procurement and manufacturing schedule identifies as a minimum:

o Details of orders and target dates;

o Any detailed design required within the manufacturing period;

o Long lead items including imported items;

o Hold points for inspection and acceptance tests and release.

The Contractor ensures that the procurement and manufacturing schedule contains sufficient detail to enable

the work to be adequately progressed in order to meet Key Dates and the Completion Date. The

procurement and manufacturing schedule must show alignment, interface and compatibility with the

Employer and Others.




2.6.2.3 Construction Schedule

The Contractor submits a construction schedule and finalized resource schedule for acceptance by the

Project Manager. This schedule satisfies the following criteria:

o Contains full details of all terminal point release requirements;

o Identifies any erection or commissioning activities that may affect other maintenance and

construction activities on the plant;

o Identifies when services are required for commissioning purposes;

o Includes an outline setting to work and commissioning schedule;

o Contain sufficient information with regard to the Activity duration and a description to enable

measurement of the progress of the Activity within the required update period;

o A description that explains and represents the performance of the Activity, including tangible

deliverables or products;

o The resources required to perform the Activity, only on those Activities that will require resource

assignment;

o A single source of responsibility or ownership.

The Contractor further submits a construction execution plan that includes man power plans, organization,

construction equipment usage, material storage and handling and preparation of construction facilities.

2.6.2.4 Commissioning Schedule

The Contractor develops a detailed commissioning schedule with sufficient detail to enable the works to be

adequately progressed in order to meet Key Dates and the Completion Date. The schedule shows

alignment, interface and compatibility with the Employer and Others.

2.6.3 Time Analysis

The Contractor takes note that, automatic manipulation of 'lags', 'overlaps', 'leads', 'relations' or 'dummies'

(with positive, zero or negative duration’s) to cause the float to remain constant when updates are performed

is not acceptable.

The Contractor ensures that all time analysis results and values of the original duration, remaining duration,

'lags' etc., are clearly reflected in the general planning report referred to in Section 2.6.12.

2.6.4 Planning Networks

The Contractor provides the program logic in network format, together with a total float report for acceptance

by the Project Manager.

The Contractor ensures that the programme network has no fewer activities than the technical and

commercial breakdowns listed in the activity schedule.




The Contractor constructs networks to reflect the possible (not probable) sequences of activities, using

resource scheduling to stagger the performance of activities into the most probable sequence.

A single time estimate for the duration of an activity is given assuming 'normal' resources are available as

required. The Contractor estimates activity durations in calendar days.

2.6.5 Time Reporting

The Contractor extracts and provides a one-month “look ahead window” from the Accepted Programme, that

furthermore shows Key Dates which are scheduled for Completion within the next reporting period.

2.6.6 Reporting on Remaining Duration

The method for reporting on activities in progress is by remaining duration, i.e. the time, in working hours or

days as required, needed to complete the activity from the report date. Once an activity has started, the

remaining duration is assessed for each update.

2.6.7 Actual Dates

The actual starting and completion date of all activities is reported.

2.6.8 Progress Reporting during Provision of the Works

The Contractor submits its progress reports on the last day of each month and if the last day is not a working

day, the preceding working day or more often as required by the Project Manager. This requirement does

not constitute a compensation event.

The Contractor submits, together with the progress reports, a written report containing the following:

Statement and report on work where delay against the Accepted Programme has occurred

(if any), together with the reasons why delay has occurred and a plan denoting the action to

be taken and the period of time necessary to recover such delay; any impact that the delay

may have on Others or an indication of Others affected by the delay.

Statement and report on those activities that are currently ahead of programme, any impact

on the progress of Others or an indication of Others affected by the delay.

The impact of any programming changes arising is reflected in revised forecast rate of

payment schedules and resource schedules.

2.6.9 Daily Progress Report

The Project Manager; the Contractor and Others meet daily to report the overall progress of erection

activities. Progress with respect to each of the following must be given:

any SHE related incidents and remedial actions or plans;




progress of previous day’s work

resources;

any deliveries of Plant, Material and Equipment’

the scheduled date of delivery of Plant, Material and Equipment’

interface, alignment and compatibility with the Employer and Others;

Contractor’s current activities progress and planned finish dates

Contractor’s planned start and finish dates for work

Planned effort for activities

Actual effort for activities

Remaining duration for activities

Percentage progress for activities

2.6.10 Weekly Progress Report

The Contractor submits weekly progress reports to the Project Manager. This report is used as a tool for the

day-to-day management of the contract. The content of the weekly report includes but not limited to the

following items:

Programme summary narrative.

Progress and performance summaries.

Completion and Key Date status.

2.6.11 Monthly Progress Report

The Contractor submits to the Project Manager a written monthly report as provided for in Section 2.6.8

above. The monthly report contains the following information as a minimum requirement:

Executive summary (narrative identifying major movement within the reporting period).

Revised Programme indicating, actual progress of work against last Accepted Programme.

A one-month look ahead work window.

Activities completed during current reporting period per discipline, including the activities of

the Employer and Others.

Activities in progress during current reporting period per discipline, including the activities of

the Employer and Others.

Activities undertaken during next reporting period per discipline, including the activities of the

Employer and Others.

Status overview by unit, by plant area, by phase.

Key issues / Items of concern and corrective actions.

Progress curves and tabular progress reports.

Cost and Cash flow.

Cost curve 'S-curve'.

Early warning log.

Compensation event log.




General planning report (computer generated).

Critical activities report.

Key event report (computer generated).

Report selecting all of the activities of the Employer and Others - (computer generated).

Updated bar charts.

Updated resource schedule and histogram (If changed).

Updated activity schedule

Forecast rate of payment schedule updated with actual progress.

Statement and report on activities ahead and behind program

Skills development progress report.

2.6.12 General Planning Report

This is a comprehensive report on all the activities included in the programme covering the network logic,

actual performance on past activities, time analysis and expected performance for future activities.

When the logic, duration’s (original and remaining), 'lags', etc, are updated, such changes are listed, flagged

or highlighted so that changes can be readily analysed by the Project Manager.

2.6.13 Critical Activities Report

The Contractor uses the same format as for the general planning report. In this instance, however, only

activities with negative and zero float are shown.

The Contractor lists activities in ascending order of negative and zero float.

2.6.14 Planner Requirements

The Contractor’s planner is experienced, qualified and must be dedicated to the Contract/Project to perform

the planning and programming requirements in accordance with this section. During execution, the

Contractor provides a full time planner at the Site.

2.7 Contractor’s management, supervision and key people

Below are the key persons referred to in clause 24 of the Contract. The Contractor includes the below listed

key persons on the Contractors organogram.

The Contractor provides the following key people as a minimum:

Dedicated Project Manager -Full time

Dedicated Project Planner- Full time

Dedicated Quality Control officers –full time

Dedicated Quality Manager as when required

Dedicated Quality Control Supervisors-full time

Dedicated Site Safety Manager-full time




Dedicated Site Safety Representatives –full time

Dedicated Technical Field Advisors

Design and Testing Engineers- as and when required

Commissioning Engineers-as and when required

For the purposes of this contract, “dedicated” means that the person is allocated only to this contract, full

time, must not be working on any other contract, must be available at Site as and when required, must be

available at Site full time during the construction phase.

In the Contractor’s tender response, the Contractor states how many of the key people are required for the

completion of the Works. The Contractor’s pricing for this provision of this activity must be stated in such a

way that the Employer is able to assess the number of dedicated persons, their job function and the extent of

their availability.

The Contractor submits, as part of the tender returnables, a company profile which includes:

A list of traceable references that adequately proves that the Contractor (or his sub-contractor) has the relevant experience with regard to the civil and structural aspects of the works

Organisational chart

The relevant qualifications and previous work experience of the key personnel. Key personnel have a minimum of five years of relevant civil and structural experience with regard to the works.

2.8 Invoicing and payment

2.8.1 General

Invoice addressed to Eskom Holdings SOC Ltd

Read “Tax Invoice”

Company VAT registration number

Eskom VAT registration Number 474010508

Invoice Date

45 Purchase Order Number

50 Goods Receipt Number

Supplier Name and Address

Vat to be indicated separately

Order Numbers to be invoiced separately

Rate/Activity to be claimed in accordance with contract

CPA invoice need to be invoiced separately

Local and foreign invoices to be invoiced separately

Tax invoice is to be emailed to email address [email protected] as soon

as it is available.

Incorrect claim (invoices) should be cancelled with a credit note referring to the incorrect

invoice and issue a new invoice


mailto:[email protected]



2.8.2 Foreign Portion Invoicing

Info of foreign beneficiary and foreign Bank account

Foreign Beneficiary Invoice (foreign Amount) to be attached to local invoice (Also to comply

to General requirements)

Bank Details and IBN No to appear on invoice

Rand amount claimed in accordance with contract

Foreign currency converted at contract rate

Amount claimed and Rand Amount to appear on invoice

Import and services to be claimed on separate invoices

VAT to be claimed separately referring to foreign invoice

Services to be paid direct overseas and may not be paid into a CFC Account

Foreign CPA calculations together with index need to be attached.

2.8.3 Import Invoices

Import documentation to be attached

Custom invoice to reflect foreign currency and amount

Bill of entry

SARS customs release notification document

Custom Worksheet

Bill of lading or Airway Bill

2.9 Insurance provided by the Employer

To be dealt with in accordance with ECC3 Core Clause 87.1, 87.2 and 87.3 and additional requirements are

also stipulated in Z Clause.

The insurance policies and procedures forms part of the Contract Data and any reference to this is contained

in the Contract Data.

2.10 Contract change management Changes during a term of the Contract are inevitable and when they occur they need to be managed within the policies and procedures of Eskom. Changes can be minor which are administrative or substantial which may affect the price and delivery. There are two ways to change a contract: a) Bilateralb) UnilateralBilateral is when both Parties (Contractor and Employer) agree that a change is necessary. The second one is the unilateral whereby the Employer may exercise a right to modify the contract without the contractor’s consent. In case of latter one, the Eskom procurement and supply chain management procedure-32-1034 must be followed.

2.10.1 Contract changes and contract Scope

Eskom commercial policy requires a competitive process, any change upon the type of goods or services needed must be consistent with what was asked during the tender stage. A contract change needs to be within the scope of what was provided during tender stage. A significant difference will not be allowed




because it had not been subjected to fair competition. Transparency is one of PPPFA requirements and as a government owned organisation had to comply with.

2.10.2 Administrative changes

These are the changes that are within the scope of contract and do not affect the originally signed contract. These changes are typically executed via a unilateral amendment. Examples include: a) Changes in addressb) Correction of typographical errors not affecting the substance of the contractc) Changes as permitted by the language of the contractd) Changes in personnel assigned to the contract.

2.10.3 Substantive changes

These are the changes that affect both Parties. They require bilateral amendments. These changes may require one of the Parties to be compensated for such changes. Examples of substantive changes include:

2.10.4 General Principles of contract change management

2.10.4.1 Engineering change will be dealt with as per 3.3.2. if either party is in doubt about whether a change falls within the definition of engineering change then it will be processed as a contract change.

2.10.4.2 Under this contract change management: a) Either party may request a contract change. All changes need to be formally communicated prior to the implementation of that change. b) Neither party makes a request that is not made in good faith or for good reasonsc) The Project Manager assesses and documents the potential impact of a proposed contract change before presenting it to the Employer’s Compensation Events Committeed) The Project Manager has the right to request reasonable amendments to a contract change request.e) The Project Manager has the right to reject a change and specify his reasons. f) No proposed contract change will be implemented by the Contractor without prior approval of the Project Manager. g) If the proposed change is of emergency in nature, approval of emergency instructions will be followed as per paragraph 2.10.7, h) Any contract change necessary to comply with a Change in Law will be implemented as set out in paragraph 2.10.3 & 2.10.4. i) Until a change is approved, signed and issued to the Contractor, then i. Unless the Project Manager expressly agrees otherwise in writing, the Contractor continues to provide the works in accordance with the signed contract as if the proposed contract change does not apply; and ii. Any discussions, negotiations or other communications which may take place between the Project Manager and Contractor in connection with any proposed contract change, including submission of any change communications, is without prejudice to each party’s other rights under this Contract. j) The Project Manager notifies in writing the Contractor stating the reasons why the Contractor has not reasonably demonstrated the need or justification for the contract change in connection with the specified event. If the Contractor disputes the notice then the matter is resolved in a risk reduction meeting. k) Where the Contractor does not approve a contract change in respect of a specified event, the Contractor notifies his decision within period of reply.

2.10.5 Costs

a) Each party bears its own costs in relation to the preparation and agreement of each change request and impact assessment.b) All contract changes are calculated in accordance with the principles set out in Price Schedule. Any cost savings resulting from the contract change will be passed on to the Project Manager by way of reduction in the charges.2.10.6 Contract Change Request.c) Either party may issue a contract change request to the other party at any time during the term of the contract. The change request is substantially in the form of Appendix 10, and must state a relevant clause and specify if it is categorised as an emergency change.




d) If the Contractor provides a contract change request, he also needs to provide an impact assessment in terms of cost, schedule, and quality.

2.10.6 Impact Assessment

a) Each impact assessment includes (without limitation): i. Details of the proposed contract change where the contract change is proposed by the Contractor including the reason for the contract change andii. Details of the impact of the proposed contract change on the contract and the Contractor’s ability to meet its other obligations under this contract, including without limitation changes to: • The works information • Accepted Programme• Other works provided by Others to the Employer including any changes required by the proposed contract change to the Project Manager.• Interface iii. Details of the estimated cost of implementing the proposed contract changeiv. A schedule for the implementation, together with any proposals for the testing of the contract changev. Where applicable details of how the proposed contract change will ensure compliance with any applicable Change in Law and vi. Such other information as the Project Manager may reasonable request in (or in response to) the change request.b) The Project Manager reviews the Impact Assessment and responds within the period of reply or as agreed with the Contractor. c) If the Project Manager requires further information regarding the proposed contract change so that it may properly evaluate the change request and impact assessment, then with the period of reply or as agreed with the Contractor, the Project Manager notifies the Contractor of this fact and details the further information that is required. The Contractor provides the relevant Impact assessment within the period of reply or as agreed with the Project Manager of such notification. The parties may repeat the process described in this paragraph until the Project Manager is satisfied that it has sufficient information to properly evaluate the change request and impact assessment.

2.10.7 Project Manager’s right of acceptance of contract changes

Within period of reply of receiving the impact assessment from the Contractor, or further information, the Project Manager evaluates the change request and the impact assessment in good faith and a) Submits all the details of the event to the Secretariat of the Employer’s Compensation Events Committee (CEC) which meets on weekly basis. b) Presents the details of the event to CEC c) Implements the recommendations of the CEC. d) Notifies the Contractor of the rejection of the proposed change. If the Project Manager rejects a proposed change, then he may explain his reasons in writing to the Contractor within period of reply or as agreed with the Contractor. e) Require further details on the change request and/or impact assessment in which the Contractor makes changes and respond within period of reply or as agreed with the Project Manager of such request. f) If the proposed contract change is recommended by the Compensation Events Committee, the Project Manager notifies the Contractor in writing. The Project Manager signs off on all deviation to the contract (drawings, specifications and other relevant documents) before the implementation of such deviations may take place

2.10.8 Contractor’s right of acceptance of proposed changes

The Contractor has a right to reject a proposed change if he believes any proposed contract change which is requested by the Project Manager: a) Would materially and adversely affect the risks to the health and safety of any personb) Would require the works to be performed in a way that infringes any Law otc) Is technically impossible to implement provided thati. The Contractor can demonstrate to the Project Manager that the proposed contract change is impossible to implement




ii. Neither the Accepted Programme nor the Works Information state that the Contractor have technical capacity and flexibility require to implement the proposed change. d) Would materially and adversely affect the Contractor’s ability to deliver the workse) Would not be possible to implement before contract completion date.f) Would cause the Contractor to breach any of the Insurancesg) Would cause the Contractor to be in breach of any existing licence, consent or permith) Would require the consent of Others to enable the contract change to be implemented and the Contractor is unable to obtain the consent of the Others.i) Would result in additional cost to the Contractor that is not proposed to be paid to the Contractor as part of change

2.10.9 Emergency Instruction contract changes

a) The emergency instruction contract change may cover technical, financial, safety and strategic aspects.b) The only person who can instruct the Contractor to implement such changes is the Project Manager. Such instructions need to be subsequently followed by a written formal communication. All changes must be documented and no payment will be made to undocumented change. c) The Project Manager is given restricted authority to cover instructions to the Contractor that are of an emergency in nature and which will result in a contract change. Such contract changes are presented to the Compensation Events Committee, by the Project Manager, for its retrospective recommendation and ratification by the Employer.

2.10.10 Authorisation of contract change

Any proposed contract changes are not authorised and the Contractor does not implement any proposed contract change until the signed letter and other signed documents (e.g. drawings, specifications) are sent to the Contractor.

2.10.11 Communications

a) For any contract change communication to be valid, it must be sent to the Contractor as applicable.b) All contract change communications may be hand delivered or sent by first class post or facsimile. Contract change communications are deemed to have been received at the following times: i. If hand delivered, than at the time of delivery or, if delivered after 16.00 hours on the next Working Dayii. If posted first class within South Africa at 10h00 on the second Working Day after it put into the post.iii. If sent by facsimile, then at the expiration of four (4) hours after the time of despatch, if despatched before 15h00 on the next Working Day, and in any other case at 10h00 on the next Working Day following the date of despatch.c) In proving delivery of a contract change communication, it will be sufficient to prove that the delivery was made, or that the envelope containing the contract change communication was properly addressed and posted (by prepaid first class recorded delivery post) or that the facsimile was properly addressed and despatched , as the case may be.

2.11 Provision of bonds and guaranteesThe form in which a bond or guarantee required by the conditions of contract (if any) is to be provided by the Contractor is given in Part 1 Agreements and Contract Data, document C1.3, Sureties.

The Employer may withhold payment of amounts due to the Contractor until the bond or guarantee required in terms of this contract has been received and accepted by the person notified to the Contractor by the Project Manager to receive and accept such bond or guarantee. Such withholding of payment due to the Contractor does not affect the Employer’s right to termination stated in this contract.

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

The Contractor submits the following for compensation event assessment:a) Quotation indicating Current market rate if not included in the short schedule of cost components




b) Labour time sheetsc) Early warning to the Project Managerd) Project Manager‘s Instructione) Percentage fee appliedf) CPA Calculation where short schedule of cost components rates were utilised g) Signed Record of decisions (ROD) or design change request form for Engineering design changesh) Revised program where key date and completion date is affectedi) Revised program where instructed to accelerate by the Project Managerj) Invoice from supplier and service providers

2.13 Training workshops and technology transferThe Contractor includes maintenance and operating manuals for all Plant and Material and equipment

supplied as part of the works. The Contractor submits the operating and maintenance manuals in both hard

and editable softs copies. All maintenance and operating manuals include the description of the Plant and

Material or equipment supplied and the AKZ numbers it applies to where applicable.

The Employer will provide training for the operation of the overall FFP.

The Contractor provides the training as described below.

2.13.1.1 C&I Training for Unit 1-6

This training is for maintenance and engineering personnel to prepare them for commissioning and

maintenance of the plant. The scope of training, as a minimum, includes field instrumentation set-up, use of

commissioning tools, signal loop drawings for trouble shooting, network configuration and system alarm

response procedure. This training is offered before cold commissioning begins. This training only focuses on

the new equipment, plant philosophies and protections provided by the FFP since the DCS system is familiar

to the C&I personnel.

The last part of training is for operating personnel to prepare them for commissioning and monitoring of the

plant after takeover. The scope of training, as a minimum, includes PFD’s, process design and operation, the

layout and information in the new mimics, the role of the control system in plant control (interlocks), the

limitations of the control system in plant control, alarms to be monitored and responded to. This training is

offered before cold commissioning begins.

Operating training need to be addressed to ensure required alarm descriptions and documentation as well as

isolation procedures are provided. The Contractor and the Employer revises the current light up procedures

which may require changes to plant settings as a result to the FFP retrofit project.

Training addresses the UPS and DC related plant to prepare maintenance and engineering personnel for

commissioning and maintenance.

2.13.1.2 C&I Training for Common Plant

This training is required on compressor’s PLC/Controller system configuration, network configuration and

logic functions for the engineering staff that will be involved with the commissioning. The training should also

focus on the new equipment, plant philosophies and protections provided for the common plants (e.g.




Compressor Plant). The last part of training includes the following as a minimum: PFD; process design and

operation; the layout and information in the new mimics; the role of the control system in plant control

(interlocks); the limitations of the control system in plant control, alarms to be monitored and responded to.

This training must be offered before the beginning of the commissioning phase of each Unit being retrofitted

to FFP’s.

3 Engineering and the Contractor’s design

Reference is made to other specification sections included in Appendices of this Works Information for

additional project requirements.

3.1 Employer’s design

The extent of the Employer’s design is as described in the Employer’s Works Information.

The Employer designed the FFP to consider and include the items as discussed and explained below. The

Employer provides drawings (Appendix J), equipment lists, datasheets, specifications and requirements for

the items discussed. The sections following are to give a better understanding of the intent of the design

such to aid in the construction of the design. Some of the works that is not discussed in this section but is

specified in the Works Information is included in the works.

The FFP is designed to control plant particulate emissions from each unit to less than 30 mg/Nm3 on an

hourly average with (n-2) compartments in service while the unit is firing the poorest quality design coal,

while experiencing air pre-heater leakage.

The FFP plant is designed for high availability, maintainability with normal maintenance tools, and will not

negatively affect current plant performance. The system design includes a requirement for the ability to re-

bag compartments with the unit online requiring no load reduction from MCR, and includes a compartment

ventilation system designed to allow for safe personnel entry temperatures to be achieved 2 hours after the

compartment is isolated from service.

3.1.1 Employer's design approach

The existing configuration of the ESP (Gas Cleaning Plant) is as per drawing 0.61/3385 revision 7, provided

for information and tender purposes only. Each unit currently has four compartments (labelled A, B, C and

D) with four inlets and four outlets. Currently, the left-hand (LH) side casing consists of compartments A and

B and the right-hand (RH) side casing consists of compartments C and D; therefore a unit consists of two

casings. The new design has one central inlet per casing and one central outlet per casing; therefore two

inlets and two outlets per unit. The new FFP structure incorporates parts of the existing ESP plant.

The FFP is located in the same footprint as the current ESP’s, thus the FFP is located between the Air

Heaters (AH) and ID Fans. There are a total of two fabric filter casings per unit. Flue gas is directed from the

AH to the FFP Inlet manifold and then to the FFP Compartments. Once the flue gas is in the compartment, it




passes up through filter bags and then exits through the central FFP outlet manifold, where after the flue is

directed to the ID Fans.

To keep pressure losses at an acceptable level, the filter bags are periodically cleaned to remove the

collected particulate cake layer. The FFP compressed air system cleans the bags with short pulses of

compressed air. The dislodged ash cake that was on the FFP bags is collected in the FFP hoppers.

3.1.1.1 FFP Inlet flue and support structure

The inlet flue is supported by two steel structures which are propped cantilevered off the FFP casing as per

the Employer’s design. The flue rests on slide bearings to allow for thermal growth, however is anchored at

one connection to one of the support structures as per the Employer’s design.

The support structures transfer forces to the casing through slide bearing connections to allow for the casing

to expand without resulting in additional internal stresses in the support structures. Each support structure is

anchored to the casing at one connection.

There are platforms to provide access to instrumentation and into the flue as per the Employer’s design.

The FFP inlet flue and support structure are situated above the access way between the boiler house and

FFP casing; this access way may also be used by Others.

3.1.1.2 FFP Compartments

There are 10 FFP compartments per FFP casing. Thus 20 FFP compartments in total. Each FFP

compartment has one inlet damper on the “dirty” gas side and two outlet dampers on the “clean gas side.

The dirty gas and “clean” gas are split through the tube sheet.

The fabric filter bags and cages hang from the tube sheet. Each compartment has broken bag detector,

temperature gauge indicator and temperature transmitter installed.

The FFP compartment further includes the pulse air cleaning system, two access doors per compartment,

vacuum breaker, view port and internal lighting, ventilation system and hopper assembly.

The compartment access doors are installed in the “inboard” and “outboard” sides of each compartment. The

compartment access doors includes an internal “screen” door that remains closed until an FFP compartment

has been cooled for safe entry of maintenance staff. The compartment access doors are opened and locked

in the open position after the FFP compartment has been isolated and vacuum has been broken. The

internal screen door is locked open on the inside of the FFP compartment when maintenance is being

performed on the inside of the FFP compartment to maintain an open exit path from the FFP compartment.

3.1.1.3 Flue Gas Expansion Joints

The FFP starts at the AH Outlet. As part of the ESP to FFP retrofit design, the outlets from the AH are

combined into one FFP inlet flue that enters the FFP inlet manifold. The flue gas then moves through the

inlet dampers into the compartments and then to the outlet manifold, before it enters the ID Fan.




There is an expansion joint between the air heater and the FFP inlet flue and another expansion joint

between the inlet flue and FFP casing. In the same way there is an expansion joint between the FFP outlet

and FFP outlet flue.

3.1.1.4 FFP Inlet Dampers

The Employer’s design includes one compartment inlet damper (louver) per FFP compartment. There are ten

FFP compartments per FFP casing; therefore there are 20 FFP compartments and compartment inlet

dampers in total per boiler unit.

The FFP compartment inlet dampers are located at the bottom of the FFP compartments. The dampers are

located in the inlet nozzles. The inlet nozzle is the transition between the FFP inlet flue and the compartment

inlet damper. The nozzles and dampers are designed such that the flue gas entering the compartment is

distributed uniformly in the FFP compartment.

The FFP compartment inlet dampers are used to prevent flue gas from entering the FFP compartments,

mostly when maintenance is being performed in the compartments. The dampers are locked in the closed

position when a compartment is isolated, even though the dampers are provided with limit switches that

sends open/closed signal to the DCS.

The inlet dampers are all pneumatically operated louver dampers that fail in place.

3.1.1.5 FFP Compartment Outlet Dampers

The Employer’s design includes two outlet poppet dampers per FFP compartment. There are ten FFP

compartments per FFP casing and two FFP casings per Unit. The FFP Outlet Poppet Dampers are located

in the clean gas chamber of each FFP compartment.

The FFP compartment outlet dampers are located at the top of the DDP compartment. The compartment

outlet nozzles are the transition between the FFP compartments to the FFP outlet flue.

The FFP compartment outlet dampers are normally open unless the compartment is being isolated. The FFP

Outlet Dampers are pneumatically actuated and fails in place. No seal air is required for the poppet dampers.

3.1.1.6 FFP Implosion Dampers

The FFP Implosion Dampers consists of two poppet style dampers installed on the FFP outlet flue. Thus a

total of four implosion dampers are provided per Unit, two per draft group.

The implosion dampers are pneumatically operated and fail in place. The implosion dampers open to the

outside of the FFP Outlet Flue. The guide shaft for the implosion dampers are on the outside of the FFP

Outlet Flue. No seal air is required for the poppet dampers.

The implosion dampers are covered by a cage for safety purposes. Access is provided to the implosion

dampers via platforms and stairs.

3.1.1.7 FFP Casing

Each FFP casing has 5 compartments on each side of the manifold. The flow to each compartment is

regulated by means of dampers. A platform is situated above the manifold and is covered with a penthouse




(weather enclosure). The penthouse transfers forces to the casing through slide bearings, however is

anchored to the casing at one connection as per the Employer’s design. Additionally, there are platforms

around the casing as per the Employer’s design.

3.1.1.7.1 Longitudinal

(side) walls

The Employer’s design does not take into consideration the additional member strength offered by the

existing stiffening on the existing side walls. In other words, the existing casing has stiffening on the outside

face of the side wall and the Employer’s design catered for stiffening on the inside of the wall. The

Employer’s drawings were developed with the assumption that the side wall is not demolished and that new

stiffening are welded to the inside face of the wall.

There are two approaches with regard to the construction of the side walls. The first option is to keep the

side walls and to stiffen it internally in accordance to the Employer’s drawings. The second option is to

remove the side walls and construct a new wall with internal stiffening. For this alternative solution, all

structures attached to these walls, such as (but not limited to) platforms, staircases and bridges are

reconnected to the new walls. The new walls are insulated and cladded.

The Contractor tenders for the first construction approach of retaining the walls and provides an alternative

solution for the second construction approach of removing the side walls and constructing new side walls.

The Employer considers the two submissions separately.

3.1.1.8 FFP Pulse Air Headers

The FFP is equipped with a pulse cleaning system. The pulse cleaning system supplies air into the inside of

the fabric filter bags. The cleaning/pulse air system is the cleaning system for removing ash deposited on the

filter bags. The pulse of cleaning/pulsing air on the inside of the fabric filter bag dislodges particulate matter

on the outside of the fabric filter bag.

The pulse air header is used to store compressed air for the pulse system. The pulse air header is sized to

supply a sufficient quantity of pulse air to each pulse valve with each cleaning pulse.

Cleaning air is provided from the cleaning/pulsing air equipment system to the pulse air headers. Each pulse

air headers has 24 pulse valves. From the pulse valves there is a flexible hose connection to the blow pipes.

The blowpipes are positioned over the holes in the tube sheet. When the FFP reaches the differential

pressure set point a sequencer will receive a signal and the pulse valves will start firing, introducing a short

blast of compressed air into blowpipes and then through holes in the blowpipe into the FFP bags, dislodging

the ash cake that has built on the FFP bags.

The FFP pulse air headers are situated on the tube sheet level. There are two pulse air headers per FFP

compartment. One on the “Inboard” and one on the “Outboard” side of each of the compartment.

The pulse air headers and pulse valves can be easily reached and maintained from the outside of the FFP

casing.




3.1.1.9 FFP Pulse Air Headers Expansion Joints

The pulse air header expansion joints separate the J-pipe from the pulse valve discharge pipe. The

expansion joint absorbs the differential expansion of the cold pulse air header versus the hot J-pipes. The J-

pipes expands with the FFP casing.

3.1.1.10 Blow pipes and J-pipes

The Tutuka FFP system has two (2) FFP casings (Casings A & B). Each casing consists of ten (10)

compartments. Each compartment has Blowpipe & J pipe components. The FFP casings are identical. The

Contractor supplies 20 FFP compartments of Blowpipe and J pipe components.

Pulse air is carried from the pulse valve to the blow pipes via the J pipes or horizontal extension pipes using

a bolted slotted flanged connection. There is an expansion joint between the pulse valve and the J pipe or

horizontal connection. The blow pipes deliver the pulse air to the top of the fabric filter bags via a hole/orifice

in the blow pipe. There is one blow pipe per row of fabric filter bags/pulse valve, one orifice over the centre of

each bag and 21 bags in a row/per pulse valve.

The alignment of the tube sheet holes and blow pipes is integral to the correct operation of the FFP.

Alignment tools have also been developed, by the Employer, for this purpose.

3.1.1.11 FFP Tube Sheet

There is a tube sheet installed in each compartment. The function of the tube sheet is to support the bags

and cages in a vertical orientation, while providing a gas tight seal between the “dirty” fluegas in the

compartment beneath the tube sheet and the “clean” fluegas in the outlet plunem above the tube sheet.

Tube sheets are made up of flat plates stiffeners welded to the underside of the tube sheet. The FFP is

designed such that the tube sheet in each compartment is the same.

The tube sheet is designed to achieve flatness, bag fit and hole location accuracy.

The tube sheet is designed to take into account practical limits. One compartment tube sheet will be made

up of a specified number of tube sheets lifted into place and seal welded.

Refer to Section 6.4.7 for requirements.

The tube sheet is tested using a Rock-No-Rock gauge to test the flatness of the tube sheet. Blanking plates

are provided to blank of tube sheet holes during operation.

3.1.1.12 Fabric Filter Bags

The fabric filter bags are the filter media for the FFP. The filter material is formed into a long tubular bag that

fits over the filter bag cage. The filter bag is tubular with a diameter of 150 mm and a length of 10 m.

The bags are manufactured with snap bands at the top of the bags for a tight fit on the tube sheet holes.

The bag material was selected to handle the normal operating temperature of the FFP.





The purpose of the filter bag cage is to support the fabric filter bag position. Fabric filter cages will be round

snap band style cages. The cage material has been selected based on the design conditions as per

Appendix E.

Cages are made up of a top support ring, coupling, bottom plate, vertical wires and horizontal wire rings. The

standard B&W cage design was used; refer to drawing B0222864 for manufacturing. This drawing covers

both two and three piece cages having 12, 16 or 20 wires, ranging from 6 to 10 meter in length.

The filter bag cage used in Tutuka FFP is a 10 meter length 150 mm diameter two piece cage.

The filter bag cages are shipped in specially made cages, refer to Section 4.3.3.1.1.

3.1.1.14 FFP Outlet flue and support structure

The flue gas from the FFP compartments leaves the compartment outlet dampers and enters the FFP outlet

flue. The flue gas is then directed to the ID fans and then exists through the chimney.

The outlet flue rests on bearings to allow for thermal growth, however is anchored at one connection to the

outlet flue support structures as per the Employer’s design. The outlet flue support structure is constructed

by the ID fan contractor. The outlet flue can only be erected once the outlet flue support structure has been

erected.

The Contractor sequences construction activities such that the ID fan upgrade project and outlet flue support

structure is completed successfully within the same outage that the outlet flue is erected. The Contractor

interfaces with the ID fan contractor through the Project Manager and shares the same Working Area.

3.1.1.15 FFP Valves

There are various valves included in the design of the FFP. The valve design criteria are included in the

valve lists included in the various parts of the Works Information.

The FFP is designed to include drain valves, pressure regulating valves, pressure control valves, root valves,

isolation valves and control valves on both the pulse air system and the instrument/control air system. The

valves are shown on the various P&ID’s and drawings for the FFP plant.

The pressure regulating valves and the pressure relief valves for the pules air system was sized on typical

values known to the Employer. Refer to P&ID’s 360-74 and 360-79.

3.1.1.16 FFP Pre-coating system

Pre-coating of the fabric filter bags before start-up, or whenever filter bags are replaced is required. The

start-up of combustors can result in incomplete combustion and create organic compounds on the fabric filter

bags. The compounds on the bags can create a non-permeable dust cake on the filter bags that can be

difficult to clean.

There are three methods of pre-coating catered for in this design. The first is the pre-coating of the entire

FFP casing after a major outage where the bags was cleaned during shut down or replaced. The FFP design

includes two pre-coating ports on the inlet to each FFP casing. An flexible hose connection is provided at




grade level for a pre-coating truck with blower to be connected. The connection to the truck splits in two lines

that go to the pre-coating inlet ports on the inlet flues.

Provision has also been made for the pre-coating of FFP compartments that has been rebagged online. The

pre-coating will happen through the FFP hoppers. There is a vacuum connection point on the hoppers where

a truck with blower can connect and introduce hydrated lime to the fabric filter bags. Refer to Appendix K

(360-81 O&M manual).

3.1.1.17 Compartment Ventilation System

There is one compartment ventilation system included in the design. The aim of the compartment ventilation

system is to cool a compartment to such a level that maintenance staff can enter the compartment to perform

online maintenance, within 2 hours of compartment isolation.

Once the compartment has been isolated and the compartment access door has been locked open the

manual compartment ventilation damper is locked in the open position. When all the interlocks are met the

pneumatically actuated compartment ventilation fan damper open. At this point the either the left hand or

right hand compartment ventilation fan will start, depending on the compartment being isolated.

There is one compartment ventilations system per FFP each having 100% capacity. The compartment

ventilations system has a cross tie between the LH and the RH compartment ventilation fans. The cross tie is

intended for redundancy. The compartment ventilation fans are arranged as one fan on each FFP casing.

The compartment ventilation fans are sized to for the cooling of two compartments per FFP casing at one

time. Each compartment ventilation fan has a jib crane installed on the same platform for maintenance of the

compartment ventilation fans, refer to Appendix M.

3.1.1.18 Jib crane and Hoist

The design includes three jib cranes per FFP unit. There is one jib crane located next to each compartment

ventilation fan and one on the outlet side of the FFP.

The jib crane located on the outlet side of the FFP lifts Plant and Material to the tube sheet level for

maintenance purposes. The jib crane lifts Plant and Material in a crate to the tube sheet level.

The jib cranes have not been selected by the Employer and have only been specified, refer to Appendix F,

section 3.2 and section 6 of this Works Information.

3.1.1.19 FFP Hoppers

The Employer’s design of the ESP to FFP retrofit retains the existing ESP hoppers.

The FFP hoppers have additional stiffening installed as well as a vacuum connection point. The vacuum

connection point can be used for either emergency offloading of the ash in the hoppers or for connection of a

truck with blower for fabric filter bag pre-coating.

Additional instrumentation is installed in the FFP hoppers to monitor the temperature in the hoppers and the

hopper levels. Due to this installation the existing agitating chains in the hoppers will be removed.




There are two FFP hoppers below each FFP compartment. Part of the inner row of hoppers is blanked off to

accommodate the central plunem / FFP inlet flue. The collected ash cake that is removed from the fabric

filter bags collect in the FFP hoppers and is removed by the DHP system.

3.1.1.20 Cleaning/Pulsing Air Equipment System

The cleaning air equipment system consists of a compressed air system delivering pulse and instrument air

and is cooled by a cooling system to ensure that Plant and Materials are maintained within recommended

and safe operating temperatures.

Cleaning air is also revered to as pulse air. This system provides pulse air to the pulse air headers for

cleaning of the fabric filter bags. The cleaning air equipment system is situated in the Tutuka FFP and DHP

compressor house which is provided by Others. The pulse air is routed to the pulse air headers from the FFP

and DHP compressor house to pulse air receivers located at the FFP units. The pulse air is then routed to

the pulse air headers; refer to P&ID’s in Appendix I.

The cleaning air system also provides instrument air to dampers and instrumentation installed on the FFP.

The cleaning air system consists of, but is not limited to the following:

3.1.1.20.1 Intake Filter

A suitable and efficient cartridge type air intake filter capable of filtering the air within the required

specifications of the compressor and can be safely and easily removed, cleaned and replaced is supplied,

tested, fitted directly onto the compressors (without the use of inlet ducting) and commissioned. The facility

to monitor the differential pressure across the filter elements is provided with the necessary alarms and trips

as per the operating philosophy of the cleaning air equipment system. Eight (8) intake filters, one (1) for each

compressor is provided.

The intake filter is situated inside the Tutuka FFP and DHP compressor house and suction for the cleaning

air compressors are taken from inside the compressor house. The compressor house is equipped with

pressurisation fans (supplied by Others) which supply filtered air, for compression to the FFP compressors,

DHP compressors, and to positively pressurise the building thus preventing contaminated dust and particles

from entering the compressor house. Reference can be made to drawings Tutuka FFP and DHP Pulse and

Instrument Air Pipe routing” with drawing number 0.61/97205 sheets 1 to 40 and “FFP and DHP Compressor

House HVAC P&ID” with drawing number 0.61/97200.

3.1.1.20.2 Compressors

Cleaning/pulsing and instrument air is produced by compressors. The cleaning air system consists of eight

(8) compressor skids, six (6) in operation and two (2) on standby. The compressors are in accordance with

the data sheet in Appendix V Section 01. All compressors are supplied as a packaged unit and include the

following but is not limited to:

Inlet filters




Inlet guide vane

Isolation and non-return (check) valves.

Blow off valves

PLC necessary to control and monitor the compressor as well as transfer signals to the plant control

system

Lube oil tank, oil pump, oil heater and necessary protections and instruments necessary for the lube

oil system

Drive motor including all necessary couplings

Base plates/ frames with damper fittings to eliminate the transfer of vibrations to the foundations

Safety valves

Instruments such as cooling water inlet and outlet temperatures and pressures and others as shown

in the drawing 0.61/97041 sheets 1 to 4

All necessary auxiliaries such as water traps and automatic drain valves

3.1.1.20.3 Air Dryers

Cleaning/pulsing and instrument air compressed by compressors are dried using air dryers. The cleaning air

equipment system contains eight (8) air dryer skids, six (6) in operation and two (2) on standby. The air

dryers are in accordance with the data sheet in Appendix V. All air dryers are supplied as a packaged unit

and include the following but is not limited to:

Dual tower desiccant air dryer.

Colour change moisture indicator.

Coalescing type moisture separator with automatic drain trap including a failure alarm.

Switching valves.

Mounted pre- filter.

Mounted after filter.

PLC necessary to control and monitor the compressor as well as transfer signals to the plant control

system.

Local pressure gauges.

Local inlet and outlet cooling water temperature gauges.

Inlet, outlet and non-return (check) isolating valves

3.1.1.20.4 Temporary Compressor and Air Dryer for Commissioning

The temporary mobile compressor and air dryer has been included to deliver air at the same quality as the

new pulse and instrument air system (-30 to -40 °C pressure dew point) at a quantity of 70 Nm3 per hour.

The temporary mobile compressor delivers air for starting up and commissioning the cleaning air equipment

system.




3.1.1.20.5 Pre and Post Filters

The cleaning air equipment system consists of eight (8) pre and eight (8) post filters situated upstream and

downstream of the air dryer respectively. The pre and post filters are in accordance with the data sheet in

Appendix V. Pre and post filters are supplied as packaged units but are not limited to the following:

Pre filter is capable of filtering the air to an acceptable quality in terms of particulate and oil content

which is safe to enter the air dryer.

Post filter is capable of filtering the air to a class 2 quality in terms of particulate and oil content.

Pre and post filters contain the instrumentation, isolations and automatic blow downs as shown in

the drawing, “Fabric Filter Plant Pulse Air System Sheets 1 to 4” with drawing number 0.61/97041

Sheets 1 to 4.

3.1.1.20.6 Compressor and Air Dryer Cooling System

The compressors and air dryers supplying pulse and instrument air is cooled by a cooling system to ensure

that Plant is maintained within recommended and safe operating temperatures. The cooling system contains

a closed circuit cooling system circulating demineralised water through a closed loop and potable water

through an open loop as per the cleaning air system operating philosophy. The cooling system is in

accordance to but not limited to the following:

Cooling towers are sized as per the heat load of the compressors and air dryers supplied by the

Contractor.

Three (3) cooling towers are in service with the ability of two (2) cooling towers to carry the full heat

load of all eight (8) compressors and air dryers (each cooling tower sized for the heat load of four (4)

compressors and air dryers).

Cooling towers contain a forced draught fan with a spray water pump on the open loop.

Four (4) 50% cooling water circulating pumps along with their isolating and non-return valves, two (2)

in service and two (2) on standby which circulates demineralised water with corrosion inhibitors

through the equipment as shown in the drawing, “ Tutuka Pulse and Instrument Air Pipe Routing”

with drawing number 0.61/97205 Sheets 1 to 40. .

A 1m3 make-up head tank as shown in the drawing, “ Tutuka Pulse and Instrument Air Pipe Routing”

with drawing number 0.61/97205 Sheets 1 to 40.

One (1) automatic open circuit and one (1) closed circuit chemical dosing systems to ensure safe,

reliable and efficient operation as per the cooling systems OEM requirements. The open circuit and

closed circuit dosing systems consist of their chemicals, dosing pumps and chemical holding

containers. Four (4) 100% pumps (two (2) in service and two (2) on standby) are supplied both open

circuit and closed circuit chemical dosing systems

The compressor and air dryer cooling system contain all the instruments as shown in the drawings,

“Fabric Filter Plant Pulse Air System Sheet 1 to 4” and Fabric Filter Plant Pulse and Instrument Air

Cooling System with drawing numbers 0.61/970410 Sheets 1 to 4 and 0.61/97044 respectively.




The Employers design for the cooling system and the make-up tank can be found in the Appendix V.

3.1.1.20.7 Compressor and Air Dryer Cooling System Circulating Pumps

Demineralised water with corrosion inhibitors is circulated through the closed cooling circuit consisting of

compressors, air dryers and the cooling tower coils using cooling water circulating pumps as shown in the

drawings, “Fabric Filter Plant Pulse Air System Sheet 1 to 4” and Fabric Filter Plant Pulse and Instrument Air

Cooling System with drawing numbers 0.61/97041 Sheets 1 to 4 and 0.61/97044 respectively. Four (4)

cooling water circulating pumps skids, two (2) in operation and two (2) on standby circulate cooling water

through the cleaning air equipment system. The cooling water circulating pumps are in accordance with the

data sheet in Appendix V. All cooling water circulating pumps are supplied as a packaged unit and include

the following but is not limited to:

Drive motor including all necessary couplings and base frame. Direct drives are preferred and no

belt driven pumps are allowed.


Instruments as per the “Fabric Filter Plant Pulse Air and Instrument Air Cooling System” with drawing

0.61/97044 respectively.

3.1.1.20.8 Pulse Air Receivers

The cleaning air equipment system contains six (6) pulse air receivers, one (1) for each unit and is located

on either side of the ash bunker as shown in the drawing, “Tutuka FFP and DHP Pulse and Instrument Air

Pipe routing” with drawing number 0.61/97205 sheets 1 to 40. The pulse air receivers are in accordance with

the data sheet shown in Appendix V and the following:

Designed to contain a volume of 15 m3

Designed for a working pressure of 800 kPa gauge pressure

Designed and constructed in accordance with ASME VIII Division 1

In accordance with SANS 347 (Category IV)

In accordance with the OHS Act (Act 85 of 1993)

Colour coded in accordance with SANS 10140 and SANS 1091

Contains as a minimum but not limited to all necessary safety valves, isolation valves,

instrumentation and the automatic condensate drains as shown in the drawing, “Fabric Filter Plant

Pulse Air Distribution Manifold” with drawing number 0.61/97042

3.1.1.20.9 Instrument Air Receivers

The cleaning air system contains two (2) instrument air receivers, one (1) in service and one (1) on standby

for all six (6) units and is located outside Tutuka FFP and DHP compressor house as shown in the drawing,

“Tutuka FFP and DHP Pulse and Instrument Air Pipe routing” with drawing number 0.61/97205 sheets 1 to

40. The instrument air receivers are in accordance with the data sheet in Appendix V and with the following:




Designed to contain a volume of 25.5 m3

Designed for a working pressure of 800 kPa gauge pressure

Designed and constructed in accordance with ASME VIII Division 1

In accordance with SANS 347 (Category IV)

In accordance with the OHS Act (Act 85 of 1993)

Colour coded in accordance with SANS 10140 and SANS 1091

Contains all necessary safety valves, isolation valves, instrumentation and the automatic condensate

drains as shown in the drawing, “Fabric Filter Plant Instrument Air Distribution” with drawing number

0.61/97043.

3.1.1.20.10 Pulse Air Piping System

The pulse air piping system includes piping, isolation and non-return valves, flanges, gaskets, bolts, isolation

and non-return valves, condensate drains, de-pressurisation valves, instruments and all other necessary

fittings to complete the piping system. The pulse air piping system in accordance with the following:

Pulse air piping is hot dip galvanised and in accordance with the piping specification CB-05 (ASTM

A106 Grade B) as per the pipe specification manual in in Appendix V.

Flanges for the pulse air piping system are hot dip galvanised and in accordance with piping

specification CB-05 (ASME B16.9) as per the piping specification manual shown in Appendix V.

Isolation and non-return (check) valves are in accordance with the piping specification CB-05 as per

the piping specification manual in Appendix V.

The pulse air piping system follows the routing as shown in the drawing 0.61/97205 sheets 1 to 40.

Flanges for are located at their respective positions as shown in the drawing 0.61/97205 sheets 1 to

40 to facilitate transportation and galvanising. Piping is fabricated, erected and installed on site after

which it is dismantled and sent for galvanising. Once galvanising is complete, piping is installed and

commissioned.

Gaskets, bolting, pipe fittings and valves are in accordance with the piping specification CB-05 as

per the pipe specification manual in Appendix V.

All pipe fittings necessary to install instruments as per the P&ID’s, “Fabric Filter Plant Pulse Air

System Sheets 1 to 4” and “Fabric Filter Plant Pulse Air Distribution Manifold” with drawing numbers

0.61/97041 Sheets 1 to 4 and 0.61/97042 form part of the pulse air piping system.

Piping in accordance with CB-05 is painted in accordance SANS 10140 and SANS 1091.

3.1.1.20.11 Instrument Air Piping System

The instrument air piping system includes piping; isolation and non-return (check) valves, flanges, gaskets,

bolts, isolation and non-return valves, condensate drains, de-pressurisation valves, instruments and all other

necessary fittings to complete the piping system. The instrument air piping system in accordance with the

following:




Instrument air piping is hot dip galvanised and in accordance with the piping specification CB-05

(ASTM A106 Grade B) as per the pipe specification manual in in Appendix V.

Flanges for the instrument air piping system are hot dip galvanised and in accordance with piping

specification CB-05 (ASME B16.9) as per the piping specification manual shown in Appendix V.

Isolation and non-return (check) valves are in accordance with the piping specification CB-05 as per

the piping specification manual in Appendix V.

The instrument air piping system follows the routing as shown in the drawing 0.61/97205 sheets 1 to

40.



which it is dismantled and sent for galvanising. Once galvanising is complete, piping is installed and

commissioned.

Gaskets, bolting, pipe fittings and valves are in accordance with the piping specification CB-05 as

per the pipe specification manual in Appendix V.


System Sheets 1 to 4” and “Fabric Filter Plant Instrument Air Distribution Manifold” and “Fabric Filter

Plant Compressor and Dryer Instrument Air” with drawing numbers 0.61/97041 Sheets 1 to 4,

0.61/97042, 0.61/97043, 0.61/97044 and 0.61/97201 respectively for the pulse air piping system.

Piping in accordance with CB-05 is painted in accordance SANS 10140 and SANS 1091

3.1.1.20.12 Compressor and Air Dryer Cooling System Piping

The cooling system piping includes piping, isolation and non-return (check) valves, including flanges,

gaskets, bolts, isolation and non-return valves, drains, air release valves, instruments and all other

necessary fittings to complete the piping system. The cooling system piping in accordance with the following:

Cooling system piping is in accordance with the piping specification CB-03 and CB-04 (ASTM A106

Grade B) as per the pipe specification manual in in Appendix V.

Flanges for the cooling system piping are in accordance with piping specification CB-03 and CB-04

(ASME B16.9) as per the piping specification manual shown in Appendix V.

Isolation and non-return (check) valves are in accordance with the piping specification CB-03 and

CB-04 as per the piping specification manual in Appendix V.

The cooling system piping system follows the routing as shown in the drawing 0.61/97205 sheets 1

to 40.



which it is dismantled and sent for galvanising for the CB-04 specification. Once galvanising is

complete, piping is installed and commissioned. Piping in accordance with CB-03 is primed and

painted in accordance SANS 10140 and SANS 1091.




Gaskets, bolting, pipe fittings and valves are in accordance with the piping specification CB-03 and

CB-04 as per the pipe specification manual in Appendix V.


System Sheets 1 to 4” and “Fabric Filter Plant Pulse Air and Instrument Air Cooling System” with

drawing numbers 0.61/97041 Sheets 1 to 4 and 0.61/97044 respectively.

Chemical dosing piping for the cooling system is in accordance with the piping specification CB-06

as per the pipe specification manual in Appendix V.

Demineralised water piping is in accordance with the piping specification CB-08 as per the pipe

specification manual in Appendix V.

3.1.1.21 Penthouse

The penthouse serves as a weather enclosure above the central platforms between the FFP left and right

hand compartments. The rafters of the penthouse were designed such that a compartment outlet damper

actuator situated between two rafters can be lifted by attaching chain hoists to the two rafters. The load of

one actuator is therefore distributed to the two rafters. The maximum load of such an actuator was assumed

to be 5kN.

3.1.1.22 Insulation and Lagging

Insulation and lagging was included on the whole of the FFP. Please refer to Appendix S.

3.1.1.23 Fire Protection

Fire extinguishers are provided at the side of the entrance door into each outlet compartment on the outside

of the casing. Each entrance contains a total of three (3) extinguishers (1 x 9kg DCP, 2 x 5kg CO2).

3.1.2 Fabric Filter Plant (FFP) Electrical System Design

The Employer has compiled a design of the electrical network required to support the FFP and auxiliaries, in

order to develop design requirements for the electrical Plant and Material required. The Contractor

completes the detail designs for the different electrical equipment in line with the requirements set out in the

works.

3.1.2.1 FFP LV Switchgear

The existing 380V Precipitator Boards A and B for Units 1 to 6 is supplied from the 11kV Unit Boards via

11/0.4kV transformers. These transformers will be re-used to supply the new 400V FFP Boards A and B for

Units 1 to 6, which are part of the works. The Contractor is responsible to decommission the old 380V

Precipitator Boards and supply and install new 400V FFP Boards. These boards will cater for all FFP

auxiliary loads. The drawings and technical schedules that convey the design requirements of these boards

are conveyed in the following documents:

Single Line Diagrams – Drawing 0.61/97097 and 0.61/97098

Load Schedules – Documents 360-459 and 360-462




Switchgear Schedules – Drawing 360-455 and 360-460

LV Switchgear Circuit Typical Schematic Diagrams – Drawings 0.61/97148, 0.61/97149,

0.61/97150, 0.61/97151, 0.61/97152, 0.61/97153, 0.61/97154, 0.61/97155, 0.61/97190,

0.61/97177

These documents are available in Appendix W1. The ID Fan auxiliary loads to be fed from these boards will

be finalised (by Others) before design freeze, for implementation. The control circuit voltage for all feeder

circuits is 230V AC. This voltage is supplied from a Dip Proof Inverters (DPIs), as per the Employer’s design.

The control voltage of the VSD (if required) will also be supplied from the respective board’s DPI supply.

Incomer and bus-section circuit breaker protection relays and control circuit require 220V DC supply. This is

to be supplied from Battery Chargers located in the same room as the LV switchgear.

3.1.2.2 FFP Cabling and Cable Racking

All power and protection cabling required for FFP loads have been identified as per the FFP design. Cables

for supplying these loads, from the new 400V FFP Boards, have been specified accordingly. The

specifications of these cables are conveyed in the cable schedules numbered 360-458 and 360-465.

The specification of all cables associated with supplying the Pulse Air Sequencers, Bag Leak Detectors and

associated Distribution Boards (DBs) for the FFPs are conveyed in the cable schedule numbered

0.61/97332.

The specification of all cables associated with supplying DC power requirements for the 400V FFP Boards

are conveyed in the cable schedule numbered 0.61/97343, 0.61/97852.

The existing cable routing and racking, from the current 380V Precipitator Boards to the exit of the boiler

house at the new FFP area, as well as those to the hopper heaters, will be re-used. The new FFP area cable

routing to be used for the FFP loads is conveyed in drawing numbers 0.61/97314, 0.61/97315, 0.61/97316,

0.61/97317, 0.61/97318 and 0.61/97319. All cabling and cable racking documents are available in Appendix

W2.

3.1.2.3 FFP Control Supplies

220V DC power is required to power the incomer and bus-section control circuits of the 400V FFP Boards,

for Units 1 to 6. This is provided through a Self-Contained Battery Charger (SCBC), otherwise known as a

Battery Tripping Units (BTU), to be housed in the same substation as these boards. The capacity

requirements for the DC power supply have been estimated to be 10A. This will be finalised once all

switchgear component information is available. The standby time required is 4 hours. The SCBCs will

receive AC supply from the 400V FFP Boards as described in the board single line diagrams (drawings

0.61/97097 and 0.61/97098). The DC single line diagrams are conveyed in drawing number 0.61/97344. All

control supplies documents are available in Appendix W3.




3.1.2.4 FFP Essential Supplies

Uninterruptible Power Supply (UPS) power is required for the Pulse Air Sequencers and Bag Leak Detectors

of the FFPs. This will be supplied from the available capacity on the unitised UPS which caters for the UPS

requirements for each Unit in Tutuka Power Station. The UPS capacity required is approximately 4.13kVA,

with a standby time 1 hour. Two supplies will be supplied from the 400V UPS Boards A and B (one per

board), for Units 1 to 6. Details of the electrical reticulation design from the UPS boards to the associated

new Distribution Boards to the PA Sequencers and Bag Leak Detectors is conveyed in the following design

documents:

Cable Block Diagrams – Drawing 0.61/97103 and 0.61/97106

Single Line Diagram – Drawing 0.61/97331.

3.1.2.5 Variable Speed Drives (VSDs)

Variable Speed Drives (VSDs) are required to supply the Ventilation Fan motors, in order for the speed of the

fans to be varied as required from the DCS. These will be housed in the 400V FFP Boards A and B. The

requirements of the VSD are conveyed in the technical schedule of Appendix Y5.

3.1.3 Cleaning Air Equipment Plant Electrical System Design

The Employer has compiled a design of the electrical network required to support the FFP and auxiliaries, in

order to develop design requirements for the electrical equipment required. The Contractor completes the

detail designs for the different electrical equipment in line with the requirements set out in the works. See

Section 3.2.16 for the requirements of the Contractor's design.

The single line diagram that shows an overview of the common plant electrical reticulation that has been

designed to support the Cleaning Air Equipment Plant is conveyed in drawing 0.61/93917.

3.1.3.1 Cleaning Air Equipment LV Switchgear

New 400V FFP Compressor House Boards A and B are required to supply all LV loads related to the

Cleaning Air Equipment Plant and the FFP and DHP Compressor House Building. The drawings and

technical schedules that convey the design requirements of these boards are conveyed in the following

documents:

Single Line Diagrams – Drawing 0.61/97099 and 0.61/97100.

Load Schedules – Documents 360-464

Switchgear Schedules – Documents 360-456

LV Switchgear Circuit Typical Schematic Diagrams – Drawings 0.61/97148, 0.61/97149,

0.61/97150, 0.61/97151, 0.61/97152, 0.61/97153, 0.61/97154, 0.61/97155, 0.61/97190,

0.61/97177




These documents are available in Appendix W1. The control circuit voltage for all feeder circuits is 230V AC.

This voltage is supplied from a Dip Proof Inverters (DPIs), as per the Employer’s design. Incomer and bus-

section circuit breaker protection relays and control circuit require 220V DC supply. This is to be supplied

from Battery Chargers located in the same room as the LV switchgear.

3.1.3.2 Cleaning Air Equipment Cabling and Cable Racking

All power and protection cabling required for Cleaning Air Equipment Plant loads have been identified as per

the Cleaning Air Equipment Plant design. Cables for supplying these loads, from the new 400V FFP

Compressor House Boards A and B, have been specified accordingly. These specifications of these cables

are conveyed in the cable schedules numbered 360-457 and 360-466.

The specification of all power and protection cables associated with supplying the 3.3kV compressors and

3.3/0.4kV transformers from 3.3kV Cleaning Air Equipment Boards A and B are conveyed in the cable

schedule numbered 360-467 and 360-1079

The specification of all cables associated with supplying DC power requirements for the 400V Compressor

House Boards are conveyed in the cable schedule numbered 0.61/97852.

The cable racking and routing requirements for the abovementioned cables, to the relevant boards and

loads, is conveyed in drawing number 0.61/97358.

The HV and MV cables for the 11/3.3kV Transformers, as well as the associated protection cables are

specified in cable schedule number 360-1379.

All cabling and cable racking documents are available in Appendix W2.

3.1.3.3 Cleaning Air Equipment Control Supply

UPS power is required for the Remote IO panels and process transmitters which will be housed in the

FFP/DHP Compressor House C&I Equipment room which forms part of the Compressor Building. The

normal supply for this UPS will be from the new 400V FFP Compressor House Boards A and B as per the

board design. The UPS capacity required is approximately 5kVA, for 4 hours. A dual redundant system has

been selected for this application. Meaning that 2x5kVA UPSs will be required, with each one being capable

of fulfilling the full capacity requirements.

220V DC power is required to power the incomer and bus-section control circuits and IEDs of the 400V FFP

Compressor House Boards. This will be provided through Self-Contained Battery Chargers (SCBC),

otherwise known as a Battery Tripping Units (BTU), to be housed in the same substation as these boards.

The SCBCs will receive AC supply from the 400V Compressor House Boards as described in the board

single line diagrams (drawings 0.61/97099 and 0.61/97100). The capacity requirement for the DC power

supply has been estimated to be 10A. This will be finalised once all switchgear component information is

available. All control supplies documents are available in Appendix W3.




3.1.3.4 Cleaning Air Equipment Transformers

As per the common plant overview single line diagram, two 11/3.3kV, 10MVA, oil-type transformers are

required to supply the 3.3KV Cleaning Air Equipment Boards A and B. The requirements for these

transformers are conveyed in a technical schedule available in Appendix Y3.

As per the common plant overview single line diagram, two 3.3/0.4kV, 630kVA, oil-type transformers are

required to supply the 400V FFP Compressor House Boards A and B. The requirements for these

transformers are conveyed in a technical schedule available in Appendix Y4.

3.1.1 FFP and Cleaning Air Equipment Plant C&I System Design

The Employer has developed and compiled a C&I system design required to support the FFP and auxiliaries.

FFP Instrument and IO list referenced by document number E263176 and E158954 respectively were

developed as per the Employer’s design (P&ID’s).

The instrument and IO list for the Cleaning Air Equipment Plant System were developed as per the

Employer’s design, see documents Z0419-000096-235 and Z0419-000097-142(360-267).

The Loop Connection Drawings as well as Cable Block Diagrams developed by the Employer indicates

connections from the field instrument via a junction box to the Employer’s existing Unit 6 DCS/Marshalling

cubicles.

Instrument and control equipment are installed in accordance with industrial best practices, see the

Employer’s instrument installation detail drawings.The Employer has developed the FFP functional logic

drawings, E262392 and compressed air plant functional logic drawings, 0.61/97353 (SHT1 – SHT 33).

The alarm lists for an FFP (360-1232) and cleaning air equipment plant system (0.61/97383) developed by

the Employer details as a minimum all the alarms that are required to be taken into consideration when

implementing the plant systems in the DCS.

Instrument Data Sheets for the cleaning air equipment plant system or alternatively FFP pulse air system is

as identified by Z0149-000131-179 and indicates the technical data for instrumentation to be installed as part

of the FFP pulse air system.

Instrument Data Sheets for the FFP system are identified by document numbers E277628, E274390,

E277540, E277628, E278035, E277946, E278044, E278079, and E278065.

Instrument and Junction box location drawings by the Employer indicate the installation locations for FFP

and cleaning air equipment plant system.

Employer drawing 0.61/97166 (Z0419-000126-251) is the control system architecture for the FFP pulse air

system and 0.61/97165 (Z0419-000125-251) is the FFP control system architecture.

The overall control of the FFP is via the DCS. The compartment inboard and outboard pulse air sequencers

control the pulsing of the pulse valves on the pulse air headers and are interfaced to the unit DCS.

The control and protection for each compressor and air drier is managed by dedicated PLC for that

compressor and air drier. This control and protection includes the control of the start-up, shutdown and anti-




surge control of each compressor and air drier. The DCS interface for the FFP pulse air system allows for

start command, stop command and pressure setpoint value to each of the compressors.

3.1.2 FFP operating and control philosophy

The Employer has designed the FFP such that the Plant operates as discussed below. The Contractor

ensures that the construction and supply is such that the Plant operates as intended.

3.1.2.1 FFP Cleaning Air Equipment System

The control philosophy for the cleaning air equipment is as described in the control philosophy, reference

number Z0419-000132-225, rev A (360-340). The Contractor supplies all Plant and Material such that the

Plant operates as described in the control philosophy, Z0419-000132-225, rev A (360-340). Please note the

following correction on Z0419-000132-225, rev A (360-340), The common controller is to maintain the

temperatures to 22+-2oC and all MCC signals are hardwired.

The cleaning air system consists of the following:

Eight (8) compressors dryers in total with six (6) in operation and two (2) on standby.

Eight (8) air dryers in total with six (6) in operation and two (2) on standby.

There is one (1) compressor and one (1) air dryer in operation per unit with each

compressor sized to supply cleaning air and instrument air for one (1) unit.

Six (6) pulse air receivers are provided (one (1) for each unit) supplying cleaning air to pulse

the FFP bags.

Two (2) instrument air receivers are provided, one (1) in operation and one (1) on standby.

Three (3) cooling towers are provided, all three (3) in operation with the ability for two (2)

compressors to carry the heat load of eight (8) compressors.

Four 50% cooling water circulating pumps two (2) in operation and two (2) on standby,

circulating water through the compressor and air dryer internals.

One open circuit chemical dosing system consisting of two (2) chemical dosing pumps, one

(1) in operation and one (1) on standby.

Closed circuit chemical dosing system consisting of two (2) chemical dosing pumps, one (1)

in operation and one (1) on standby.

3.1.2.2 FFP Control Philosophy

The control philosophy and system requirements specification for the FFP is as described on the SRS

(System Requirements Specification) document, E211426. The Contractor supplies all Plant and Material

such that the Plant operates as described in the SRS document, E211426.

3.2 Parts of the works which the Contractor is to design

The Contractor’s design includes the work which, although not expressly noted, can reasonably be inferred

from the Works Information, the only exclusion being that which are specifically stated to be free issued or

otherwise to be provided by the Employer.




If the Contractor considers that additional Plant and Material are necessary for operation of the Plant or

Employers design, the Contractor quotes this additional Plant and Materials and supplies an explanation of

why it is necessary to the Project Manager for acceptance. The Contractor only proceeds if acceptance from

the Project Manager is received.

Where the Contractor requires additional information to design and install certain areas of the Plant or

Employers design, the Contractor confirms the details with the Project Manager a week before continuing

with the works. These clarifications and requirements are discussed at the weekly progress meetings.

The Project Manager may review, but will not approve, the Contractor’s work to check compliance. It is the

Contractor’s responsibility to ensure compliance with the Works Information. The Contractor supplies as built

information and drawings to the Employer prior to handover.

3.2.1 Flue Gas Expansion Joints

The Contractor designs and installs all flue gas expansion joints as per the Section 6.4.9 and the Employer’s

drawings section 7.1, which contains specifications and information with regard to the number of expansion

joints, associated locations and required movements.. This includes, but is not limited to, expansion joint

belts, pillows (packing), shields, nuts, bolts, flat washers, lock washers, retainer bars, and expansion joint

frames.

The Contractor submits the expansion joint designs and drawings to the Project Manager for acceptance.

The Contractor supplies the expansion joint manufacturer’s specification.

3.2.2 FFP Compartment Inlet Dampers

The Contractor selects the FFP compartment inlet (louver) dampers such that it can operate in all conditions

as per Section 6.4.5 and the additional requirements included in Appendix G. The number of dampers and

design conditions is as per Appendix G.

The Contractor installs the lock mechanism as required by the Employer’s design. The Contractor installs the

instrumentation required by the Employer’s design to operate the dampers. The Contractor commissions the

dampers.

The area where the dampers are installed is limited / restricted and the Contractor installs the dampers,

actuators, instrumentation and other auxiliaries such that maintenance can be easily performed. The

Contractor connects the instrumentation air to the pneumatic actuator via a flexible connection and supplies

all Plant and Material required for routing the instrumentation / control air to the inlet dampers. The pipe

routing is completed as per P&ID’s 0.61/97023 sheet 1 and 2 and 0.61/97024 sheet 1 and 2. The pipe

routing is performed as per section 3.2.20.11.

The compartment inlet dampers open to the direction as shown on the Employers drawings.

The Contractor selects the dampers such that it fits into the area provided in the inlet nozzles for the

dampers as shown on the Employers design. Refer to drawings 0.61/97726, 0.61/97730, 0.61/97083 and

sectional view 0.61/97083.




3.2.3 FFP Compartment Outlet Dampers

The Contractor selects the FFP compartment outlet dampers as per requirements in section 6.4.5 and the

additional specifications included in Appendix H. The Contractor is responsible for supplying all Plant and

Material required for a complete operating system. This includes all valves, actuators and instrumentation

required for the safe and dependable operation of the FFP.

The number of FFP Outlet Dampers to be selected by the Contractor is included in Appendix H.

The area where the dampers are installed is limited / restricted and the Contractor installs the dampers,

actuators, instrumentation and other auxiliaries such that maintenance can be easily performed. The

Contractor connects the instrumentation air to the pneumatic actuator via a flexible connection and supplies

and installs all Plant and Material required for routing the instrumentation / control air to the inlet dampers.

The pipe routing is completed as per P&ID’s 0.61/97023 sheet 1 and 2 and 0.61/97024 sheet 1 and 2. The

pipe routing is performed as per section 3.2.20.11.

The Contractor selects the dampers such that it fits into the area provided in the inlet nozzles for the

dampers as shown on the Employers design. Refer to drawings 0.61/97724 and drawings referenced on

0.61/97724.

3.2.4 FFP Implosion Dampers

The number and size of Implosion Dampers to be selected by the Contractor is included in Appendix H.

The Contractor selects the FFP Implosion Dampers and all associated Plant and Material as per Section

6.4.5 and the additional specifications included in Appendix H. The Contractor is responsible for supplying all

Plant and Material required for a complete operating system. This includes all valves, actuators and

instrumentation required for the safe and dependable operation of the FFP.

The Contractor installs the dampers, actuators, instrumentation and other auxiliaries such that maintenance

can easily be performed. The Contractor connects the instrumentation air to the pneumatic actuator via a

flexible connection and supplies and installs all Plant and Material required for routing the instrumentation /

control air to the inlet dampers. The pipe routing is completed as per P&ID’s 0.61/97022. The pipe routing is

performed as per section 3.2.20.11.

The Contractor selects the dampers such that it fits into the area provided in the outlet flue as shown on the

Employers design. Refer to drawings 0.61/97242, 0.61/97243, 0.61/97246 and drawings referenced in

section 7.1.

The Contractor installs the safety platforms around the implosion dampers and ensures that the installation

does not negatively affect the operation or maintenance of the Implosion dampers. Refer to drawing

0.61/97248 and 0.61/97249 and as per Employers design drawings as listed in section 7.1.

3.2.5 FFP Compartment

The Contractor constructs the FFP compartments as per the Employers design refer to drawings listed in

section 7.1. Refer in particular to drawing numbers 0.61/97916, 0.61/97918, 0.61/97921, 0.61/97922 and

0.61/97923.




The FFP compartment further includes the pulse air cleaning system, two access doors per compartment,

vacuum breaker, view port and internal lighting, ventilation system and hopper assembly.

The Contractor selects the light fitting for the internal lighting and installs the lighting such that it can

withstand the temperatures and pressures in the FFP Compartments.

The Contractor installs and supplies all the Plant and Material and Equipment to construct the FFP

compartments and install all Plant and Material.

3.2.6 FFP Casing Foundations

3.2.6.1 The Contractor prices the scope as described below as part of a Takeout Option:

The bearing pressure of a number of existing foundations which supports the FFP calculated with the new

design loads is exceeding the assumed allowable bearing pressure of 850kPa. This bearing pressure has

been assumed from a not complete Geotechnical investigation which indicated mudstone and sandstone in

the surrounding area. As part of the tender; the Contractor is to use the information supplied in Table 1 to

provisionally design and price a solution that accommodates the new design loads.

Upon contract award the Contractor conducts a Geotechnical Investigation as set out in section 6.1.2 to

establish the allowable bearing pressure. The Contractor uses the information from his Geotechnical

Investigation in conjunction with the information supplied in Table 1 to verify the provisional design solution.

In the case that the provisional design solution is no longer feasible the Contractor updates or provides a

new solution using the information from his Geotechnical Investigation to accommodate the new design

loads.

The Contractor’s solution is to be functional in its entirety such that any existing structural elements affected

or used in the Contractor’s design are verified and modified if required. The Contractor’s solution is confined

to a system which is situated below grade and does not structurally affect the columns of the support

structure. The Contractor submits his solution in the form of a report, inclusive of all calculations to the

Project Manager for acceptance prior to commencement of the works.

Refer to drawings listed below for information with regard to the foundation numbers and layout in Table 1

0.61/3946

0.61/5959

0.615968

For all other foundation drawings refer to sections 7.1. Table 1: Units 1-6 Un-factored foundation loads

Foundation

No.

Base Size

(m x m)

Hx (kN) Hz (kN) Py (kN) Maximum Bearing

Pressure (kPa)

B2 2 x 2 0 -148.32 1740.349 986

B3 2 x 2 129.1 178.2 2719.9 1298




B5 2 x 2 -124.5 -172.6 2493.8 1321

D2 2 x 2 -5.8 156 2479.4 965

D3 2 x 2 127.2 177 2264.2 1278

D5 2 x 2 -121.5 -174.8 2242.8 1208

3.2.6.2 The Contractor is responsible for the following:

The Contractor backfills all excavations and reinstates the concrete ground slab where it was cut or

damaged.

The Contractor repairs or reinstates road surfaces that were damaged or excavated.

The Contractor repairs or reinstates underground services that were damaged or temporarily

rerouted.

The Contractor rebuilds the concrete bund walls that were removed.

Post outage general civil activities (where required) may consist of making concrete good, recasting of bund

walls and slabs type activities.

3.2.7 Access doors

The Contractor fabricates/manufactures, supplies, installs and commissions all access doors as per

Employers design refer to section 7.1. This includes compartment access doors with screen doors and flue

access doors. Refer in particular to drawing numbers 0.61/97904, 0.61/97905, 0.61/97906, 0.61/97907,

0.61/97908, 0.61/97909, 0.61/97910, 0.61/97911, 0.61/97912, 0.61/97913, 0.61/97914, 0.61/97915,

0.61/97917, 0.61/97919, 0.61/97920, and 0.61/97924.

3.2.8 FFP tube sheet

The Contractor supplies all Plant and Material, shop detailing, shop labor, consumables etc. as needed to

fabricate and ready for shipment all tube sheet ship units as shown on the Employers Design Erection

Arrangement (DEA) drawings listed in the Appendix J and Section 7.1. Refer in particular to drawing

numbers 0.61/97952, through to 0.61/97962.

Ship units includes (but is not limited to) the following:

• Tube sheet assemblies

• Composite beams ( if required)

• Landing / Seal angles

• Connection plates

• Tube sheet lifting rigs

• Special Alignment tools

• Blanking plates




• Rock-No-Rock gauges

• All bolts, nuts, fasteners

The Contractor develops shop details and fabricate based on the information presented in this Works

Information and on the DEA drawings.

3.2.9 FFP Pulse Air Header

The pulse air headers are installed, by the Contractor, with support attachments for a control panel, brackets

for tank support, pulse valves, flexible connections, sequencer control cards, instrumentation with wiring,

blowpipes and power supply and control input wiring to sequencer. The quantities are as per appendix P.

The Contractor fabricates/manufactures, supplies, installs and commissions all access doors as per

Employers design refer to Appendix J. Refer in particular to drawing numbers 0.61/97218 through

0.61/97221 and 0.61/97708 through 0.61/97710.

The pulse air headers are completely shop assembled and tested, by the Contractor. This includes all wiring,

tubing, valves etc. The Contractor carries out inspections to verify tolerances to the Contractors

manufacturing drawings as per section 4.4.8.

The Contractor fabricates, tests, supplies, installs and commissions the pulse air headers according to the

requirements as per Section 6.6.2. The Contractor is completely responsible for engineering design.

3.2.1 FFP Valves

The Contractor is responsible for final materials selection based on the information given in the Works

Information, refer to Section 6.4.6, Employers design drawings Appendix J and the applicable valve lists.

The locations of the valves are as per the drawings supplied to the Contractor in Appendix J. If the locations

of the valves need to be altered to meet the requirements of the Works Information the Contractor indicates

the locations on drawings and submits for acceptance to the Project Manager before continuing with

installation.

The Contractor supplies drawings of each type of installed valve to the Employer. The Contractor supplies as

built information and drawings to the Employer prior to handover.

The Contractor completes the data pages included in Appendix L.

3.2.1.1 Pulse valves

The Contractor selects the pulse valves as per the design conditions given in Appendix P, Appendix I and

according to the requirements in Section 6.4.6.

3.2.2 FFP Pulse Air Header Expansion Joint

The Contractor supplies 20 FFP compartments of pulse air header expansion joints per boiler unit.

The Contractor’s supplies all Plant and Materials, shop detailing, shop labour, consumables etc. as needed

to fabricate and ready for shipment all pulse air header expansion joints, as per the requirements in section

6.6.3 and Employer design refer to section 7.1. (Drawings 360-515, 360-514, 360-513, 360-512)




3.2.3 Blow pipes and J-pipes

The Contractor supplies 20 FFP compartments of Blowpipe and J pipe components per boiler unit.

The Contractor’s supplies all Plant and Materials, shop detailing, shop labour, consumables etc. as needed

to fabricate and ready for shipment all Blowpipe & J pipe ship units as shown on the Employers Design

Erection Arrangement (DEA) drawings listed in the Section 7.1 and as per the requirements in Section 6.6.4.

Refer in particular to 0.61/97228 through 0.61/97236.

Shop units include (but are not limited to) the following:

Individual Blowpipes w/welded end flanges & caps

J Pipe assemblies

End support channels

All support plates, channels, flange supports

All lap and seal bars

All bolts, nuts, washers

All alignment tools & gauges

The Contractor develops shop detail drawings based on the information presented in this Works Information

and on the Design Erection Arrangement (DEA) reference drawings in Section 7.1.

All temporary handling and shipping braces and tie-downs required to safely transport the blowpipe or J pipe

ship units to Site is included by the Contractor. This includes design of all necessary temporary braces and

ties, by the Contractor.

3.2.4 Penthouse

The Contractor supplies and installs all Plant and Material as per Employers design drawings included in

section 7.1.

The rafters of the penthouse were designed such that a compartment outlet damper actuator situated

between two rafters can be lifted by attaching chain hoists to the two rafters. Refer to section 3.1.1.7.

The Contractor is to stencil the rafters such that it clearly communicates this limitation.

3.2.5 Filter Bag Cages

The Contractor is completely responsible for engineering design for the filter bag cages. The Employer

reviews, but does not approve, the Contractor’s work to check compliance. It is the Contractor‘s responsibility

to ensure compliance with the Employers Works Information.

The splice connection used to connect the filter bag cage sections together is of the type shown in Appendix

E (Drawing B0222864). The Contractor must use a splice connection of this type to connect filter bag cage

sections together. Other splice connections may be used but must be accepted by the Project Manager prior

to use. The Contractor controls design and fit of the coupling connection to accomplish the following:

The cages will not deform during assembly.




The cages can be disassembled and re-assembled as needed over the life of the cage without

deformation of the cage or loss of joint integrity.

The assembled coupling connections are firm and not work loose during the life of the cages.

The coupling connection / joint resist a minimum vertical load of 45 kg. A maximum load shall be

established at the time of the sample inspection.

Tools are not permitted for joint disassembly.

The Contractor manufactures the fabric filter cages as per the drawings provided in Appendix E. The

drawings provided are not manufacturing drawings and the Contractor creates the manufacturing drawings

as per the requirements as set out in this Works Information.

The Contractor supplies, as a minimum, the following Plant and Materials:

Filter bag cages

Field Service

Sample cages

Installation

Shipping crates

The Contractor supplies the filter bag cages and performs the installation of the FFP bags and cages. The

quantities required and fabric filter bag cage material is as per Appendix E.

The Contractor supplies 4 sample cages to the Project Manager to check the fit with the fabric filter bags.

Bags supplied by Others.

The Contractor supplies the filter bag cages as per the design conditions and requirements given in

Appendix E and section 6.4.4.

3.2.6 FFP Hoppers

The Contractor modifies the existing hoppers as per the Employer’s design. The Contractor interfaces with

the DHP contractor as the hoppers and the DHP upgrade are constructed within the same outage. Due to

the work that needs to be performed below the FFP hoppers, by Others, the Contractor designs,

manufactures and installs blanking flanges in the place of the DHP knife gates to prevent objects from falling

onto the DHP and FFP hoppers.

The Contractor supplies all the Plant and Material, detailing, instrumentation selection, installation, cabling

and cable routing as required to perform the modifications and installations in the hoppers. The Contractor

inspects the hopper heaters and refurbished the hopper heaters where required.

Due to the installations in the hopper the existing agitating chains in the hoppers are removed by the

Contractor.

The Contractor designs, manufactures, installs and removes again the blanking flange as per Employers

requirement in section 6.4.13. The blanking flange is part of the works.




Refer to Section 6.4.13 for requirements and section 7.1 for Employers design. Refer in particular to

drawings 0.61/97159 through 0.61/9712 and 0.61/97728.

3.2.7 FFP Pre-coating System

The Contractor supplies all Pre-Coat System Plant and Material including pipe, fittings, flanges, fasteners &

gaskets, pipe supports and miscellaneous materials as shown on the Employers design drawings and

fabricate into shop pipe spools as shown.

The Contractor supplies all Plant and Materials, detailing, shop labor etc. as needed to fabricate the following

Pre-Coat system components:

Pipe, fittings, flanges

Nuts, bolts, gaskets

Isolation valves

Pipe supports

“Y” type pipe flow splitter

Injection ports (no lances)

Camlock type Fitting (for connection to Truck)

The design conditions and requirements are as per Section 6.4.12 refer to Employer design is section 7.1

and in particular to drawings 0.61/97813 through 0.61/97855 and 0.61/97755.

3.2.8 Compartment Ventilation System

The Contractor supplies/fabricates the compartment ventilation system and installs/erects and commissions

the system. Each compartment ventilation system includes;

Centrifugal fan assembly (heavy duty industrial quality)

Bearings

Bearing thermocouple (including heads and terminals for connecting field wiring)

Inlet silencers

Bird screens

Fan isolation damper

Fan discharge piping with flanges

Split housing with drain

Flush bolted cleanout door

High efficiency motor

Direct coupling drive with OHSA coupling guard

Shaft and bearing guard

Shaft seal

Unitary base with spring isolation

Startup assistance

Anchor bolts

Fan supports

Connecting ductwork and expansion joints\insulation and lagging




Power supply for motors, controls and instrumentation

Motor starters

Compartment ventilation system isolation dampers

The list above is not necessarily a complete listing of all Plant and Material. The Contractor is responsible

for supplying all Plant and Material required for a complete operating system. This includes all valves and

instrumentation required for the safe and dependable operation of the system.

The Contractor selects the compartment ventilation fans as per the Works Information.

The Contractor provides the compartment ventilation fans as per the requirements in Appendix M, section

6.4.10 refer to Employer design is section 7.1 and in particular to drawings 0.61/97711 through 0.61/97715,

0.61/97173 through 0.61/97176, 0.61/97770, 0.61/97771 and 0.61/97025.

3.2.9 Jib crane and Hoists

The Contractor selects the jib crane such that it is fit for purpose. The Contractor determines the boom radius

required to lift equipment, for maintenance, from ground level to tube sheet level. The Contractor mounts and

provides support structures for the jib crane. The Contractor installs the jib crane at the positions indicated

on the Employer’s GA drawings.

The Contractor selects/supplies and installs the jib crane required to lift equipment from grade to tube sheet

level as well as one jib crane for each compartment ventilation fan. The Contractor designs the support

structure for the compartment ventilation fans jib cranes. The Contractor selects the capacity of the jib cranes

according to the weight of the Plant and Material to be lifted to perform maintenance on the compartment

ventilation fans. The Contractor installs the jib cranes at the positions indicated on the Employer’s GA

drawings.

The Contractor supplies the Plant and Material identified below, the supply of each jib hoist includes the

following;

Jib Hoist

Tagline Festoon system

Power Panel, starters, control pendants

Onsite checkout and maintenance of hoists

Installation

The list is not necessarily a complete listing of all Plant and Material. The Contractor is responsible for

supplying all Plant and Material required for a complete operating system. This includes all Plant and

Material required for the safe and dependable operation of the system.

The Contractor provides the electrical power to the jib hoists.

3.2.10 Site Construction Workshop

The Site Construction Workshop is a permanent structure and is part of the works which is handed over to

the Employer for future use. The Employer did not perform any design work on the site construction

workshop. The site construction workshop is designed in full by the Contractor.




The Contractor submits the design in full, a design report and all the accompanying structural drawings to the

Project Manager for acceptance at least 2 months prior to fabrication. Upon acceptance, the Contractor

supplies a full set of final structural drawings and fabrication drawings, together with a full set of final clearly

detailed calculations.

No dimensions are obtained from a drawing by scaling. All drawings show full endorsement by a

Professional Engineer (including the engineer’s Professional Engineering Number and signature).

The design adheres to the following minimum requirements:

The Contractor designs and constructs the Site Construction Workshop in accordance to the

relevant South African National Standards, Regulations and Codes of Practice.

The design of the civil, structural and building works and the specification of the materials,

methods and erection are carried out or verified by a professional engineer registered with the

Engineering Council of South Africa. This design is submitted to the Project Manager for his

acceptance.

The Contractor considers and assesses all loading conditions, stresses, or other factors which

are relevant or critical to the design.

The workshop is designed for a 2 hour fire rating.

The workshop houses a 10t overhead travelling crane to cross the whole workshop (gable to

gable) to perform the onsite manufacturing as required by the Contractor’s design.

The appearance of the building is such that it matches that of the existing buildings of the Power

Station terrace.

The minimum footprint of the building is 20m by 60m.

The distance from the top of concrete of the ground slab to the bottom of steel of the crane girder

is 10m. The Contractor submits a motivation to the Project Manager for the case where the

Contractor requires the crane girder at a higher elevation due to clearance considerations.

The workshop does not contain ablution facilities or offices.

All designs, drawings and specifications are reviewed and approved by the responsible engineer prior to

submission to the Project Manager for acceptance. Drawings are not reviewed without the relevant approved

design calculations. Design calculations include, at minimum, the following:

Design criteria statement and general information

o Design philosophy, including a narrative that explains the design approach

o List of applicable codes and literature that was used in the design

o Assumptions made with regard to the design (verified and unverified)

Calculation of loads

o All the applicable loads as required

o All load combinations are according to SANS 10160 or applicable international

standards

Structural stability and soil verifications




Crack width calculation checks for concrete structures

Bending, axial and shear design calculations

Connection calculations

Baseplate and holding down bolt calculations, as per the Contractor’s design

Applicable soil information are recorded

Fatigue verification if required

The structural design, fire protection, drainage, ventilation, earthing, lighting and small power is the

responsibility of the Contractor and is submitted to the Project Manager for acceptance.

The Contractor adheres to the following Employer fire protection/detection standards;

240-54937439 Fire Protection/Detection Assessment Standard

240-54937450 Fire Protection & Life Safety Design Standard

240-56737448 Fire Detection and Life Safety Design Standard

The Contractor’s design engineer carries out inspections at appropriate stages to verify that the construction

is carried out in accordance to his design.

The Contractor constructs the workshop in the FFP Contractor Laydown and Fabrication area as indicated

on drawing 0.61/96022. The final layout, location and orientation of the building in this area are subject to

approval of the Project Manager. The Contractor produces as-built drawings of the Site Construction

Workshop 1 month after the construction is completed.

3.2.10.1 Electrical installation

The Contractor designs the entire electrical installation for the workshop. This includes the earthing and

lightning protection designs.

Once the Contractor has completed the design of the electrical installation and determined the power

requirements thereof, the Contractor sends the total power requirements to the Project Manager.

The Project Manager informs the Contractor of the point of supply from which the workshop will be supplied

from. The Contractor designs for and provides the works for everything from this point, including the main

supply cable.

The site construction workshop electrical installation complies with Eskom’s Coal Fired Power Stations

Lighting and Small Power Installation Standard (240-55714363).

3.2.11 Slide Bearings

The Contractor installs all slide bearings and anchors as required by the Employer’s design and drawings

refer to section 7.1. The Contractor submits the bearing manufacturer’s specification to the Project Manager

for acceptance.

3.2.12 Pulse Air Receiver Tank Bases

Pulse air receiver tanks are placed on the existing ground slab as indicated on 0.61/97205 for the case

where the weight of a pulse air receiver tank is 35kN or less. The Contractor informs the Project Manager if




these pulse air receiver tanks weigh more than 35kN and awaits instruction from the Project Manager. The

Contractor investigates the adequacy of the ground slab depth by means of core drilling if holding down bolts

are required for the tanks. The Contractor informs the Project Manager if the slab thickness is not enough to

accommodate holding down bolts and submits a design for the required air receiver tank bases to the Project


3.2.13 Control Power Supplies

Finalisation of the capacity requirements (battery and power) of the FFP Cleaning Air Equipment control

power UPS and the Self-contained Battery Chargers for the Compressor House LV boards and the FFP LV

boards is the responsibility of the Contractor. This is to be sized to satisfy the identified control load

requirements of the LV switchgear assemblies, the process transmitters and the I/O panels during normal

and standby time conditions.

The Contractor produces load profile data for the final sizing of the SCBC for acceptance by the Project

Manager. The required standby time for each SCBC is 1 hours, including 6 opening and 5 closing incomer

circuit breaker operations.

The Contractor also produces load profile data for the final sizing of the Control Instrumentation UPSs in the

Compressor House for acceptance by the Project Manager. The required standby time for each UPS is 4

hours.

The Contractor then completes Technical Schedule A and B for the required SCBCs and submits this to the

Project Manager for acceptance.

3.2.14 FFP Earthing and Lightning Protection

The new equipment of the FFP will be earthed and bonded to the existing ESP structure that will remain in

place. The Contractor determines the earthing and lightning protection requirements for the FFP area and

produces earthing and lightning protection designs for the FFP area. The designs developed are in line with

the Eskom Earthing and Lightning Protection standard 240-56356396.

3.2.15 FFP Area Lighting and Small Power

A new Lighting and Small Power Installation is required for the FFP areas on the Units; i.e. walkways,

platforms, on top of the casing, around the casing, in the penthouse, inside FFP compartments (clean gas

chamber), etc. This scope includes new FFP Area Lighting Distribution Boards on top of the FFP casings, all

associated cabling, luminaires and welding sockets (single phase and 3-phase). The Contractor determines

all the Lighting and Small Power requirements for the FFP area and produces designs for these. The

Contractor ensures that all the Lighting and Small Power Plant and Material selected are adequate for the

environment where they are to be installed. The designs developed are in line with the Eskom Lighting and

Small Power standard 240-55714363.

The requirements for the lighting installed on the inside of the FFP compartments are included in Section

6.3.8.




3.2.16 Electrical Equipment Detail Design

The Contractor provides detail designs and produces detailed shop drawings for the following electrical

equipment in line with the Employers designs specified in Section 3.1:

All Low Voltage Switchgear

All Battery Chargers (or Battery Tripping Units)

All Transformers

All Variable Speed Drives (VSDs)

All electrical equipment detail designs are to comply with the requirements referenced in Section 6.3. The

Contractor submits these detail designs to the Project Manager for acceptance.

3.2.17 Low Voltage Switchgear

The Employer has provided typical schematic diagrams for the different circuits applicable to the works. The

Contractor uses these to develop the actual wiring schematic drawings for the switchgear.

The Contractor conducts an assessment of the short circuit withstand rating of the smaller cables (less than

6mm2), and selects the correct Short Circuit Protection Device (SCPD) required to provide adequate current

limiting such that the cables are protected from a fault occurring at any point of the cable length. The

Contractor submits this this assessment to the Project Manager for acceptance.

The Contractor reviews the LV Switchgear VSD feeder standard schematic design (0.61/97154) done as part

of the Employers, and confirms the suitability of the control methodology and switchgear interface with the

VSD manufacturer/supplier. Any changes required are communicated to the Project Manager.

3.2.18 Cabling and Cable Racking

The Contractor determines all mounting and installation detail requirements for all cable racking as specified

in the Employer’s design. The Contractor provides detailed cable racking and routing design drawings for all

the cable racks in the FFP area and the FFP and DHP Compressor House building, for acceptance by the

Project Manager, before the cabling installation begins.

The Contractor determines any additional cable racking requirements for securing transformer cables to be

routed to the transformer terminal boxes in the transformer bays. The Contractor submits the detailed

drawings for these to the Project Manager for acceptance, before purchase.

The Contractor determines the most optimal cable route for the 11kV cables to be installed from Substation

East and Substation South to the new 10MVA transformers. These routes are to make maximum use of

existing cable tunnels and no digging of new trenches for direct burial is allowed. The proposed routes are

submitted to the Project Manager for acceptance before implementation.

The Contractor investigates the most optimal routes from the 400V UPS Board A and B, Units 1 to 6, to the

beginning of the new cable racking for the UPS load cables on the FFP area (see Employer’s design). The

proposed routes are to be submitted to the Project Manager for acceptance before implementation.




Where existing cable racks are to be re-used, the Contractor produces a report on assessment of the loading

of these cable racks. This report discusses assessments on the loading capacity of the racks vs the loading

level, the general condition of rack, condition of mounting, etc. This report is to be submitted to the Project


The Contractor safely removes all existing cables used for the obsolete and redundant loads. Where removal

of some cables is not feasible or practical, these cables are decommissioned, cut, marked as “Not Used” and

left on the cable racks in a state that does not adversely affect normal operation of operational cables.

The Contractor ensures that cabling and cable racking is in accordance with 240-56227443: Requirements

for Control and Power Cables for Power Stations Standard (Rev 1).

3.2.19 Diesel Generator Boards Modification

The Contractor implements modifications on the 380V Diesel Generator Boards A and B of Unit 1 to 6.

These modifications are required to supply critical ID fan auxiliary loads. One such load has been identified

as the Lube Oil Pumps for the ID fan. Other critical ID fan auxiliaries (if any) will be communicated by the

Project Manger when this information is available.

The modifications may require upgrade of existing functional units or equipping of spare functional units.

The Contractor is required to supply and install the required switchgear and controlgear required to safely

supply and protect these loads in accordance with 240-56357424: MV and LV Switchgear Protection

Standard (Rev 1).

3.2.20 Cleaning Air Equipment System

The Contractor supplies, installs, optimises, tests and commissions a cleaning air system including

auxiliaries which supplies compressed air used to clean/pulse the FFP bags.

3.2.20.1 Intake Filter

The Contractor supplies, installs, test and commissions eight (8) intake filters, one (1) for each compressor

as per the Employer’s design.

3.2.20.2 Cleaning Air Compressors

Cleaning/pulse and instrument air is produced by compressors. The Contractor supplies, installs, test and

commissions eight (8) compressor skids, six (6) in operation and two (2) on standby. Compressors are

supplied as packaged units together with their auxiliaries, inlet filters, non – return valves, suction and

discharge valves, blow off valves, inter-stage water traps and automatic condensate drains as per the

Employer’s design. Compressors are installed by the Contractor in accordance with the drawings 0.61/97205

Sheets 1 to 40.

3.2.20.3 Cleaning Air Dryers

Cleaning/pulse and instrument air compressed by compressors are dried using air dryers. The Contractor

supplies, installs, tests and commissions eight (8) air dryer skids, six (6) in operation and two (2) on standby.

Air dryers are supplied as packaged units together with water separators, non-return valves, change over




valves, isolation valves, automatic condensate drains and post filters as per the Employer’s design. Air

dryers are installed by the Contractor in accordance with the drawings 0.61/97205 Sheets 1 to 40.

3.2.20.4 Temporary Compressor and Air Dryer for Commissioning

The Contractor makes provision for a temporary mobile compressor and air dryer to be installed to start up

and commission the permanent cleaning/pulse and instrument air systems. The permanent pulse and

instrument air system operates continuously without tripping for a period of one month after start up and

commissioning before the temporary mobile compressor can be removed from site.

3.2.20.5 Pre and Post Filters

The Contractor supplies, installs, test and commissions eight (8) pre filters and eight (8) post filters as per the

Employer’s design.

3.2.20.6 Compressor and Air Dryer Cooling System

The compressors and air dryers supplying cleaning/pulse and instrument air will require a cooling system to

ensure that the system is maintained within recommended and safe operating temperatures. The Contractor

supplies, installs, test and commissions a closed circuit cooling system circulating demineralised water

through a closed loop and potable water through an open loop as per the philosophy described in the

Employers design.

The Contractor supplies, installs, tests and commissions a 1m3 make-up head tank as per the Employer’s

design as shown in the drawing 0.61/97205 Sheets 1 to 40.

The Contractor supplies, installs, tests and commissions one (1) automatic open circuit and one (1) closed

circuit chemical dosing system to ensure safe, reliable and efficient operation as per the cooling systems

OEM requirements. The open circuit and closed circuit dosing systems consist of their chemicals, dosing

pumps and chemical holding containers. The Contractor supplies, installs, tests and commissions four (4)

100% pumps (two (2) in service and two (2) on standby) are supplied both open circuit and closed circuit

chemical dosing systems

The compressor and air dryer cooling system contain all the instruments as per the Employers design as

shown in the drawings 0.61/97041 Sheets 1 to 4 and 0.61/97044 respectively.

The Contractor takes note of the Employers standards for demineralised and potable water production,

document numbers 240-53113712 and 240-55864764 respectively. The Contractor ensures that the new

cooling system supplied is in accordance with the Employers chemistry for cooling water standard: document

number 240-55864767.

Demineralised water for the closed circuit cooling system is provided by the Employer however the

Contractor makes provision for an interface at a flange to receive demineralised water top op supply. The

demineralised water top up supply is received via piping which is provided by Others as shown in the

drawings “Tutuka Power Station FFP Pulse and Instrument Air Cooling System” with drawing number




0.61/97044 “Tutuka FFP and DHP Pulse and Instrument Air Pipe routing” with drawing number 0.61/97205

sheets 1 to 40 as well as in the LOSS diagram with number LOSS-06 – 08-02.

Potable water for the open circuit cooling system is provided by the Employer however the Contractor makes

provision for an interface at a flange to receive potable water supply for make-up. The potable water make

up supply is received via piping which is provided by Others as shown in the drawings “Tutuka Power Station

FFP Pulse and Instrument Air Cooling System” with drawing number 0.61/97044 “Tutuka FFP and DHP

Cleaning/pulse and Instrument Air Pipe routing” with drawing number 0.61/97205 sheets 1 to 40 as well as in

the LOSS diagram with number LOSS-06-08-03.

The Contractor makes provision for a common terminal point from the cooling towers to be available for

Others. The blow down media is taken away from the blow down terminal point (provided by the Contractor)

to the dirty water drains by Others as shown in the drawings 0.61/97044 as well as the LOSS diagrams with

number LOSS-06-08-05

3.2.20.7 Compressor and Air Dryer Cooling System Circulating Pumps

Demineralised water with corrosion inhibitors is circulated through the closed cooling circuit consisting of

compressors, air dryers and the cooling tower coils using cooling water circulating pumps. The Contractor

supplies, installs, test and commissions four (4) 50% cooling water circulating pumps skids, two (2) in

operation and two (2) on standby. The cooling water circulating pumps are in accordance with the Employers

design. The Contractor supplies, installs, tests and commissions all cooling water circulating pumps as a

packaged unit and includes the following but is not limited to:

Drive motor including all necessary couplings and base frame. Direct drives are preferred and no

belt driven pumps are allowed.


Instruments as per the drawing 0.61/97044.

3.2.20.8 Cleaning/Pulse Air Receivers

The Contractor designs, supplies, installs, tests, cleans and commissions six (6) pulse air receivers, one (1)

for each unit and is located on either side of the ash bunker as shown in the drawing, “Tutuka FFP and DHP

Pulse and Instrument Air Pipe routing” with drawing number 0.61/97205 sheets 1 to 40. The pulse air

receivers are in accordance with the Employers design. The Contractor supplies all drawings for the air

receivers and obtains the necessary approvals from inspection authorities. The Contractor provides the

Employer with allowable nozzle loadings for the pulse air receivers to ensure that the pipe supports (supplied

by Others) upstream of the pulse air receiver are designed such that the nozzle loadings of the pulse air

receiver are within allowable limits.

3.2.20.9 Instrument Air Receivers

The Contractor designs, supplies, installs, tests, cleans and commissions two (2) instrument air receivers,

one (1) in service and one (1) on standby for all six (6) units and is located outside Tutuka FFP and DHP

compressor house as shown in the drawing, “Tutuka FFP and DHP Pulse and Instrument Air Pipe routing”




with drawing number 0.61/97205 sheets 1 to 40. The instrument air receivers are in accordance with the

Employers design. The Contractor supplies all drawings for the air receivers and obtains the necessary

approvals from inspection authorities.

3.2.20.10 Cleaning/Pulse Air Piping System

The Contractor designs, fabricates, erects, supplies, installs, tests, cleans and commissions the pulse air

piping system including flanges, gaskets, bolts, isolation and non-return valves, condensate drains, de-

pressurisation valves, instruments and all other necessary fittings to complete the piping system in

accordance to the Employers design. The Contractor installs the pulse air piping system as per the routing

shown in the drawing “Tutuka FFP and DHP Pulse and Instrument Air Pipe routing” with drawing number

0.61/97205 sheets 1 to 40. The Contractor takes cognisance that a section of the pulse air piping supplied,

installed, tested and commissioned by the Contractor will be situated on pipe supports provided by Others as

shown in the drawing “Tutuka FFP and DHP Pulse and Instrument Air Pipe routing” with drawing number

0.61/97205 sheets 1 to 40 and in the LOSS diagram with number LOSS-SS-AA-03. The Contractor provides

the Employer with pipe support loadings for the sections of piping supported by Others.

The Contractor fabricates, erects and installs piping on site after which it is dismantled and sent for

galvanising. Once galvanising is complete the Contractor installs and commissions the pulse piping system.

The Contractor supplies, installs, tests and commissions all pipe fittings necessary to install instruments as

per the P&ID’s, “Fabric Filter Plant Pulse Air System Sheets 1 to 4” and “Fabric Filter Plant Pulse Air

Distribution Manifold” with drawing numbers 0.61/97041 Sheets 1 to 4 and 0.61/97042 respectively for the

pulse air piping system.

The Contractor designs fabricates, supplies, installs, tests and commissions insulation and lagging/ cladding

on piping sections where the hot face temperature exceeds 60 degrees Celsius or higher. Insulation is

designed such that the resulting maximum cold face temperature of the surface material of the insulation is

55 degrees Celsius at an ambient temperature of 30 degrees Celsius. Insulation and lagging/ cladding are in

accordance with the Employers thermal insulation standard with document number 240-56247004.

3.2.20.11 Instrument Air Piping System

The Contractor designs, fabricates, erects, supplies, installs, cleans, tests and commissions the instrument

air piping system including flanges, gaskets, bolts, isolation and non-return valves, condensate drains, de-

pressurisation valves, instruments and all other necessary fittings to complete the piping system in

accordance to the Employers design. The Contractor installs the instrument air piping system as per the

routing shown in the drawing “Tutuka FFP and DHP Pulse and Instrument Air Pipe routing” with drawing

number 0.61/97205 sheets 1 to 40. The Contractor takes cognisance that a section of the instrument air

piping supplied, installed, tested and commissioned by the Contractor is situated on pipe supports provided

by Others as shown in the drawing “Tutuka FFP and DHP Pulse and Instrument Air Pipe routing” with

drawing number 0.61/97205 sheets 1 to 40 and in the LOSS diagram with number LOSS-SS-AA-03. The

Contractor provides the Employer with pipe support loadings for the sections of piping supported by Others.




The Contractor fabricates, erects and installs piping on site after which it is dismantled and sent for

galvanising. Once galvanising is complete the Contractor installs and commissions the pulse piping system.


per the P&ID’s, “Fabric Filter Plant Pulse Air System Sheets 1 to 4” and “Fabric Filter Plant Instrument Air

Distribution Manifold” and “Fabric Filter Plant Compressor and Dryer Instrument Air” with drawing numbers

0.61/97041 Sheets 1 to 4, 0.61/97042, 0.61/97043, 0.61/97044 and 0.61/97201 respectively for the pulse air

piping system.

3.2.20.12 Compressor and Air Dryer Cooling System Piping

The Contractor designs, fabricates, erects, supplies, installs, cleans, tests and commissions the cooling

system piping including flanges, gaskets, bolts, isolation and non-return valves, drains, air release valves,

instruments and all other necessary fittings to complete the piping system in accordance to the Employers

design. The Contractor installs the cooling water system piping as per the routing shown in the drawing

“Tutuka FFP and DHP Pulse and Instrument Air Pipe routing” with drawing number 0.61/97205 sheets 1 to

40. The Contractor takes cognisance that a section of the cooling water system piping supplied, installed,

tested and commissioned by the Contractor will be situated on pipe supports provided by Others as shown in

the drawing “Tutuka FFP and DHP Pulse and Instrument Air Pipe routing” with drawing number 0.61/97205

sheets 1 to 40 and in the LOSS diagram with number LOSS-SS-AA-03. The Contractor provides the

Employer with pipe support loadings for the sections of piping supported by Others.


per the P&ID’s, “Fabric Filter Plant Pulse Air System Sheets 1 to 4” and “Fabric Filter Plant Instrument Air

Distribution Manifold” and “Fabric Filter Plant Compressor and Dryer Instrument Air” with drawing numbers

0.61/97041 Sheets 1 to 4, 0.61/97042, 0.61/97043, 0.61/97044 and 0.61/97201 respectively for the pulse air

piping system.

3.2.20.13 Pipe spool fabrication

Pipe spool fabrication is in accordance with the requirements in section 6.

3.2.20.14 Piping Supports

The Contractor designs, supplies, constructs and commissions pipe supports from the pulse air receivers up

to the pulse valves as shown in the drawing “Tutuka FFP and DHP Pulse and Instrument Air Pipe routing”

with drawing number 0.61/97205 sheets 1 to 40. Pipe supports are in accordance with the specification in

section 6. The Contractor conducts a pipe stress analysis for hot and cold operation, dead weight and

vibrational loads to optimise the spacing and selection of pipe supports.

3.2.21 Cleaning Air Compressor Plant Control System Design (Common Plant DCS)

A common plant system such as FFP cleaning/pulse air system (sometimes referred to as cleaning air

compressor plant) is as per the Employer’s design. This plant system is controlled and monitored from

OPCR YOKOGAWA DCS. The Contractor ensures that the common plant system interfaces to new

YOKOGAWA DCS cubicles.




The Contractor implements the functional logic drawings and control philosophies in the DCS according to

the requirements of the Employer’s design. The Contractor is responsible for the correct implementation of

control philosophies and the functional logic drawings in the OPCR YOKOGAWA DCS.

The Contractor provides for the new HMI MIMICS design of the common plant system.

3.2.22 FFP Control System Design

The Contractor develops, designs and implement in the DCS, the logics that ensures that minimum oil

residuals are transferred to the fabric filter bags when oil firing during startup, deloading and shutdown

sequencing. At startup, a minimum of three PF mills running are required before the DCS could send a

Cleaning command to the sequencers which is maintained during cleaning and normal operation. The

Contractor refers to the SRS (E211426) for Pulsing/Cleaning on Mills and Oil Firing Conditions when

designing and implementing the logics.

3.2.22.1 FFP Unit 1-3 control system

The Contractor implements the functional logic drawings and control philosophies in the DCS as per the

Employer’s design. The Contractor liaises with Others in Unit 1 - 3 to correctly implement control

philosophies and the functional logic drawings in the DCS (by Others).

The Contractor provides for the new HMI mimics design in Unit 1-3 and interfaces with Others to correctly

implement the HMI mimics.

3.2.22.2 FFP Unit 4-6 control system

The Contractor implements the functional logic drawings and control philosophies in the DCS as per the

Employer’s design. The Contractor is responsible for the correct implementation of control philosophies and

the functional logic drawings in the existing ABB P14 DCS in Unit 4-6.

The Contractor provides for the new HMI MIMICS design in Unit 4-6.

3.2.22.3 FFP control philosophy (SRS)

The Contractor designs for pulsing/cleaning on Mills and Oil Firing Conditions as per the requirements sated

in the SRS, E211426. The Contractor develops the logic and ensures that the correct signals are utilised to

correctly implement this requirement.

3.2.22.4 FFP Implosion Protection

Three pressure transmitters are installed per casing on the outlet ducting for implosion protection and should

be utilised to activate open the implosion dampers when the negative excessive pressures are reached

during normal operation. The Contractor implements implosion protection as per the SRS, E211426. The

Contractor either uses the 2oo3 voting system or averaging method to ensure that the implosion dampers do

not open due to a bad signal or spurious signals.

The Contractor implements “a warning suction/vacuum pressure high alarm” to prevent opening of the

implosion dampers and causing un-necessary fluctuation in the furnace pressure. This warning suction

pressure ‘high’ alarm will be activated at a suction pressure XX% (to be determined by the Contractor) below




the casing design pressure. The warning “High Alarm” should warn the operators in the UCR before the

implosion damper can be activated (Note that in the SRS, the first implosion opens when PRESSURE ≥ -

4.2KPa). On a “a warning suction/vacuum pressure high alarm”, the operator must immediately reduce the

boiler load thus arrest the suction pressure so that the dampers will not be activated and a potential boiler

trip will not occur.

3.2.23 Field Equipment Design

The Contractor ensures that all manufactured and installed enclosures such as junction boxes and panels

adhere to the Employer’s standard, 240-56355815.

The Contractor utilises the CFD provided by the Employer to determine the length of the thermocouple

element (TE) into the inlet and outlet ducting.

3.2.24 Insulation and Lagging

The Contractor performs all insulation and lagging as per Appendix S.

3.3 Procedure for submission and acceptance of Contractor’s design

The Contractor submits all designs to the Project Manager for acceptance.

The Project Manager reviews the Contractor’s submitted documents. The Contractor ensures adherence to

the Works Information and that a technically sound design approach is incorporated. Specific information

required from the Contractor during tender phase is set-out in the Vendor Document Submittal Schedule

(VDSS), Appendix B.

Each document submitted to the Project Manager requires a transmittal note (refer to Employer’s template

240-71448626 for minimum metadata requirements) from the Contractor. The Contractor includes

interpretation of results in every report compiled. Project Manager review cycle is in-line with NEC contract

requirements and is finalised during contract negotiations with the Contractor.

3.3.1 Design Review Documentation

The Contractor conducts design reviews of the Contractor’s design as per the Contractor’s official design

review procedure.

The Contractor further takes note of the Employers Design Review Procedure (240-53113685) and

participates in all design reviews as specified by the Employer. The Employer may “Authorise”; “Authorise

with Comments” or “Not Authorise with Comments”. If required, the Contractor makes the necessary

revisions on the documentation and ensures acceptance is obtained from the Project Manager. The

Contractor includes these design reviews as part of the schedule and suggests appropriate timing for such

reviews.

The following design reviews below are conducted, by the Employer, as per the design review procedure

(240-53113685);

Contract Award Review




Design Freeze Review(s) (Detail Design) System Integrated Design Review (Detail Design) Pre-Commissioning Review (per unit) Hand-over Review

Design Freeze reviews can be conducted as End-of-Phase Design Reviews or as a series of Interim Design

Reviews with the aim to design freeze a system or subsystem/asset in order to enable subsequent designs

to progress. The number of design freeze reviews is accepted by the Employer.

3.3.1.1 Contractors Responsibilities in Employers Design Review Process The Project Manager conducts Design Reviews as per the Employers design review procedure; Participation

of the Contractor in the Employers Design Reviews consists of:

The Project Manager conducts Design Reviews as per the Employers design review procedure

and the Contractor presents (the design developed by him) and participates in the design

review.

If any fundamental errors were found in the designs or further actions are required, the

Contractor addresses all concerns raised and revises the designs.

The Contractor submits the documents for another Design Review session once all designs are

revised according to the concerns raised by the Project Manager.

If no fundamental errors are found in the designs during the Design Review session, the Project

Manager compiles the Design Review minutes and report.

The Contractor reviews the report and minutes. If the report/minutes are not acceptable, the

Contractor submits comments to the Project Manager.

The Project Manager accepts the Contractor’s design once the report is accepted and signed by the

Employer’s project team and the Contractor.

3.3.2 Engineering Change Procedure

The Contractor takes note of the Employer’s Engineering Change Procedure (240-53114026, Rev 1). An

engineering change includes any proposed engineering change originating from the Contractor or Employer

from an established design baseline by the design review procedure.

3.3.3 Time Required for Acceptance of Designs

Not later than one (1) month after receipt, the Project Manager returns one (1) copy of the drawing/

document marked as “Authorised”; “Authorised with Comments” or “Not Authorised with Comments”, as may

be appropriate. The notations “Authorised” and “Authorised with Comments” authorise the Contractor to

proceed with the manufacture of the Plant and Material covered by such drawings/ documents subject to the

corrections, if any, indicated thereon, unless otherwise stated. Where prints or drawings/ documents are “Not




Authorised with Comments” the Contractor makes the necessary revisions on the drawings/ documents and

submit further copies for acceptance in the same procedure as for the original submission of drawings/

documents. Every revision shows by number, date and subject in the revision block on the drawing and

documents.

3.4 Use of Contractor’s design

All documentation as specified in this document is supplied to the Project Manager by the Contractor this

includes any detail design drawings, as well as fabrication drawings, that is required for maintenance or

requested in this Works Information.

The Employer reserves the right to issue the Contractor’s design or drawings to other contractors for

purposes of maintenance, spares, verifications, modifications in future or any other purposes required by the

Employer; the Employer has total rights to use the design as the Employer requires.

Any detail design drawings required for maintenance purposes is supplied to the Project Manager, by the

Contractor. The detail design drawings or fabrication drawings supplied to the Project Manager by the

Contractor can be supplied to any maintenance partner that the Employer wishes to enter into a partnership

with during the life of Tutuka Power Station.

The Contractor notes that all GA, assembly and dismantling drawings become the property of the Employer

upon Completion of the works. The Employer is permitted to purchase replacement parts off these drawings

from the lowest cost suppliers.

3.5 Design of Equipment

The Contractor is required to furnish and maintain the necessary tools and Equipment to provide the Works

(including all manual and power tools, cranes, elevators, lifts, etc.). The Contractor is encouraged to share

Equipment use where possible and locate cranes in the main work areas based on coordination with Others.

The Contractor is advised to mark all tools, scaffolds, and other Equipment for ease of identification.

The Contractor is responsible for all temporary works that is used by the Contractor to complete the works.

The Contractor submits all designs or proposals for temporary works to the Project Manager. The Project

Manager reviews but does not accept the temporary works. The Project Manager comments on the

effectiveness, necessity or risk of the temporary works or Equipment, to allow the Contractor to provide the

Works efficiently and without delay. For details on expected temporary works refer to section 5.1.13.

3.6 Equipment required to be included in the works

The Contractor provides all labour, installation tackle, gear and tools, vehicles, rigging tackle, consumables,

site workshops, site offices, stores and any other facilities, equipment and cleaning materials required to

provide the works.




The Contractor provides all the test equipment for testing the individual modules, the sub-assemblies and the

functional groups for site testing, commissioning and performance testing.

The Contractor provides all necessary scaffolding required to complete the works.

3.6.1 Special Tools

Special tools are equipment required to maintain and operate the supplied Plant and Material, which must be

manufactured specifically for the application. Special tools are included in the works.

The Contractor includes two (2) sets of special tools and breakout pricing required for the

installation/erection, operating and routine maintenance of the supplied piece(s) of Plant and Material,

including any applicable lifting/hoisting and rigging equipment or tools. Tools supplied by the Contractor is

new and of first class quality. Tools are transported to Site, by the Contractor, in a suitable container clearly

marked with the name of the equipment for which the tools are intended.

In addition Contractor includes all special tools as shown on the DEA drawings. The Contractor includes the

Rock-No-Rock gauge and blanking plates as special tools.

3.7 As-built drawings, operating manuals and maintenance schedules

The Contractor submits all documentation that includes as-built drawings, operating manuals and

maintenance schedules and designs to the Project Manager for acceptance.

The Project Manager reviews the Contractor’s submitted documents. The Contractor ensures adherence to

the Works Information and a technically sound design approach is incorporated. Information required from

the Contractor is set-out in the Vendor Document Submittal Schedule (VDSS), Appendix B and as per the

Works Information and MDL; refer to section 2.2.5, 2.6.2.1 and 3.7.

The Contractor brings to the Project Managers attention any changes that are required to the Employers

design. All changes proposed by the Contractor are motivated and submitted as a mark-up of the Employers

design documents for acceptance by the Project Manager. The engineering change process will be used to

update the Employers design, refer to section 3.3.2.

3.7.1 2D drawings and 3D Models.

The preferred system for 2D drawings and 3D models is SmartPlant. The Contractor adheres to the Smart-

Plant Data Take-On Standard (240-107305502).

The Contractor ensures that creation, issuing and control of Engineering Drawings are in accordance with

the Employer’s Engineering Drawing Standard (240-86973501). The Contractor’s structural steel and

concrete drawings further complies with SANS 10143 Building Drawing Practice, and the Southern African

Structural Steelwork Detailing Manual by the Southern African Institute of Steel Construction.

The Contractor submits editable electronic drawings in MicroStation (DGN/DWG) format, and scanned

drawings in PDF format. Drawings issued to the Employer are not be “Right Protected” or encrypted.




Drawings submitted by the Contractor to the Project Manager for acceptance includes the compiler(s) and

approver(s) signatures.

Electronic drawings have a water mark indicating the approval phase of a drawing and hardcopies are to be

stamped to indicate the approval phase.

The Contractor's drawings are complete in every respect (including welding details which are fully described)

and are checked by the Contractor prior to submission to the Project Manager for acceptance. All drawings

show full endorsement by a Professional Engineer (including Pr. Eng Number and signature on all drawings

such as all civil drawings).

Any drawing prepared or made for the purpose of carrying out the works is the property of the Employer and

may be used by the Employer as the Employer deems fit.

3.7.1.1 Fabrication and erection drawings

The Contractor prepares fabrication and erection drawings for all civil and structural components of the

works. Immediately upon receipt of the Employer’s design drawings, the Contractor satisfies himself that the

drawings contain all the information required for the preparation of his own shop drawings and supporting

calculations, together with any other necessary details. The Contractor submits these drawings to the

Project Manager for acceptance.

The Contractor's drawings and supporting calculations are submitted at least one month before

commencement of fabrication. Before the commencement of fabrication, the Contractor obtains acceptance,

from the Project Manager, for the shop details in writing. The acceptance given by the Project Manager does

not absolve the Contractor from liability and responsibility for the accuracy of the drawings.

Any detail design drawings, manufacturing or fabrication drawings that are required for maintenance and all

structural fabrication drawings are supplied to the Project Manager by the Contractor.

3.7.1.2 Demolition and dismantling

The Employer provides drawings that indicate the components of the structure which is to be demolished at

a high level. The Contractor uses the Employer’s drawings to create demolition requirements which are

presented on drawings by the Contractor. The Contractor ensures structural stability is maintained for all

conditions of demolition/dismantling. The Contractor submits detailed demolition and dismantling method

statements to the Project Manager for acceptance prior to any work being carried out. Included in this

method statement are all drawings and design calculations required for the demolition/dismantling.

3.7.1.3 Structural drawings

The Contractor prepares structural drawings for all the components of the works which the Contractor

designs. The Contractor submits these drawings to the Project Manager for his acceptance.




3.7.1.4 As-built drawings

The Contractor prepares as-built drawings for all the components of the works which he constructed and

designed. The Contractor submits these drawings to the Project Manager for his acceptance.

3.7.1.5 Redlined Drawings

Any and all changes required by the Contractor for construction or manufacturing, that impact or change the

Employers design is redlined on drawings. The redline drawings includes notes for clarification purposes.

The Engineering change process will be used in the case of any design changes.

4 Procurement

4.1 People

4.1.1 Minimum requirements of people employed on the Site

The Contractor does not alter previous decisions communicated to the Employer or Others without the

Employer’s acceptance or agreement.

All semi-skilled and non-skilled employees required for this project shall be sourced from the Local to site

communities in Lekwa Local Municipality. The Employer will make the local to site employment database

available to the Contractor for recruitment of non-skilled and semi-skilled employees. The Contractor is not

allowed to recruit non-skilled and semi-skilled employees from the gates of Tutuka Power Station or any

other process other than the utilisation of the employment database which will be provided by the Employer.

Any new foremen/Supervisors appointed by the Contractor after Contract Date or during provision of the

works are fully conversant with respect to details of the methodology and communication process existing,

prior to accessing the Site. The Contractor provides the CVs and all other relevant information of the

replacement employees to the Project Manager.

Permits for foreigners – The Contractor informs the Project Manager of any need to employ foreigners and

on acceptance by the Project Manager, the Contractor arranges permits for such employees. The Contractor

informs the Project Manager when the services of specialists are required. The Contractor ensures interface

with Others is managed before commitment is made to bring specialist to Site.

The Contractor ensures that the Contractor’s workforce is trained and competent to perform their respective

duties. The Contractor provides CVs and proof of qualifications of his key persons (listed in Section 2.7 of

this Works Information) as a returnable schedule.

The Contractor provides for professionally registered (Pr.Eng) and experienced design engineers.




4.1.2 BBBEE and preferencing scheme

The Employer requires the Contractor to either maintain or improve the Broad Based Black Economic

Empowerment Recognition Level (B-BBEE Recognition Level) as at the Contract Date.

Penalty on B-BBEE Recognition Level:The Contractor shall be penalised 0.5% of the committed contract value if the Contractor or its

Sub-Contractor(s) fails to maintain the B-BBEE Recognition level as provided at contract award.

4.1.3 Skills Development, Local Content and Local Production

The Employer, as a State Owned Enterprise, is mandated to comply with Preferential Procurement Policy

Framework Act (“PPPFA”). The Employer’s contribution to this initiative is to agree on Local Content and

Local Production as well as Skills Development targets as committed by the Contractor to achieve. This

commitment is achieved through leveraging the Employer’s procurement spend in a manner that allows

flexibility within the business in order to accommodate government local development initiatives and policies.

4.1.4 Localisation Compliance

For the duration of the contract, the Employer will retain 2.5% of any invoice (excluding VAT) payable at the end of each periodic interval as security for the fulfilment by the Contractor of its SD&L obligation.

The penalty for non-compliance will be 2.5% of the value of the contract for each percentage not met, and it shall be deducted from the final payment.

4.1.5 Skills Development

Skills Development will not be a criterion that is weighted, however, the Contractor is encouraged as part of

the tender submission to propose skills development initiatives in terms of the skills required for a project.

Skills Development Targets will be agreed with the prospective Contractor during negotiation stage. This will

form part of the contractual obligation with the successful Contractor. If applicable, the Contractor will be

required to keep accurate records and provide the Project Manager with monthly reports on the Contractor’s

actual delivery against the agreed skills development targets.

The Contractor shall submit to the Project Manager a detailed Labour Resource Plan that reflects both retained and new jobs to be created by the project.

All trainees required for this project shall be sourced from the Local to site communities in Lekwa Local Municipality. The Contractor shall follow the recruitment processes, i.e. advertising on local media.

The Employer shall verify all the candidates before the placement.

The penalty for non-compliance on Skills Development will be 2.5% of the value of the contract for each percentage not met.




4.1.6 Job Creation

Job creation proposals by tenderers will not form part of the tender evaluation criteria. It is however, part of Eskom’s contribution towards the Government’s job-creation initiative as contained in the New Growth Path (NGP) and the New Development Plan (NDP).

The Employer has made a number of empowerment commitments to the local communities surrounding the areas where it conducts its construction activities. Amongst these, are commitments to be considered for local empowerment possibilities in its procurement strategy. In doing this, the Emp loyer is seeking to ensure that the local communities benefit from its procurement spends through wealth generation and capacity development; and that this benefit is spread as widely as possible throughout the community.The Contractor to propose to the Employer the number of semi-skilled and unskilled labourers that will be sourced from local to site in support of this empowerment commitment to the local communities.Furthermore, all semi-skilled and non-skilled employees required for this project shall be sourced from the Local to site communities on Lekwa Local Municipality.

Note: The Employer will make the local to site employment database available to the Contractor for recruitment of non-skilled and semi-skilled employees. The Contractor is not allowed to recruit non-skilled and semi-skilled employees from the gates and any other process other than the utilisation of the employment database which is with the Employer.

4.2 Subcontracting

4.2.1 Preferred subcontractors

The Contractor shall sub-contract a minimum of 30% of the value of the contract. The Contractor shall sub-contract to an exempted micro-enterprise (EME) Level 1 or 51% or more, Black Ownership / Qualifying Small Enterprise (QSE) Level 1 with 51% or more, Black Ownership that has the capability and ability to execute the sub-contracting scope.

In the event that the Contractor intends to sub-contract after the contract award, the2nd and 3rd Tier Companies should be submitted to the Employer for evaluations and classification.

The Contractor shall not subcontract with their subsidiary companies as this may be interpreted as subcontracting with themselves and / or using their subsidiaries for fronting. Where the Contractor subcontracts with a subsidiary this must be declared in tender documents.

4.2.1.1 Reporting

The Monthly report for SD&L shall be submitted on matrix to the Project Manager on or before the 7th day of every month.

a. Sub-contracting Reporting

Sub-Contractors (2nd and 3rd Tier) spending shall be done monthly. This requirement is only for reporting purposes.

The report should state the following:- Reporting Month - Contract title and Contract number- Sub-Contractor Vendor Name- Activity / Bill item related to contribution- Payment Value for month – in ZAR- Sub-Contractor’s Invoice number- Main Contractor’s Payment Reference Number- B-BBEE Credentials (including percentage of black ownership).

Each page of the report shall bear a signature of the Contractor declaring accurate reporting.




The Sub-contractors’ invoices should reflect the Project, Site and Activity to the related service/s performed.

First preference shall be given to Local to site Black Owned entities. Local to site “means all areas that fall within Lekwa Municipality.

b. Skills Development Reporting:

1. The Contractor shall submit a detailed Skills Development Plan within 28 days after contract award.

2. Skills development progress reporting shall be done on a Quarterly basis

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

All skills developed shall be retainable for a minimum period of 3 years.

The correctness of the figures shall be audited / verified at any time by the Employer.

SUMMARY OF SD&L TARGETS:

Criteria Minimum TargetLocal Content to SA 85%Local Content to Site 10%Procurement from BO 12%Procurement from BWO 8%Procurement from SBE 8%Procurement from BYO 2%Procurement from BPLwD 1%

Core Skills 2 Safety Officers and 2 Environmental Officers

Critical Skills 30 Artisans, 2 Quantity Surveyors and 1 Planner

Scarce skills 10 Mechanical Technicians and 1 Design Engineer

Jobs Created Contractor to ProposeJobs Retained Contractor to propose

*Local Content to Site refers to but not limited to Accommodation, Transport, Fuel, etc. The Employer will

make accommodation and transport database available to the Contractor

**Local to Site “means all areas that fall within Lekwa Municipality

Corporate Social Investment (Not a weighted criterion)




The tenderer is required to submit a CSI Proposal to a value of at least 2% of the Contract value as a direct benefit to the Local to site communities

Criteria Expected CSI (%) Target (%) ProposalCSI 2% 2%

4.2.2 Enterprise Development (ED)

The Contractor shall submit an Enterprise Development plan that seeks to provide assistance or acceleration

of black enterprises leading to growth and sustainability of their business. A detailed ED plan that shows

impact to the beneficiary should be submitted to the Employer for approval prior to contract award. ED

implementation plan should include:

Clear objective;

Priority interventions;

Key performance indicators; and

A concise implementation plan with clearly articulated milestones.

First preference shall be given to Local to site EME level 1. Local to site “means all areas that fall within Lekwa Municipality.

4.2.3 Subcontract documentation, and assessment of subcontract tenders

a) The Contractor uses the NEC3 form of subcontract for all subcontracts

b) The Contractor provides the the B-BBEE status level verification certificates for all Subcontractors.

c) The Contractor informs the Employer when it subcontracts parts of the works

d) The Contractor only employs qualified sub-contractors and suppliers as specified in section 4.2.1.

4.2.4 Limitations on subcontracting

a) The Contractor does not sub-contract more that 25% of the contract value to another enterprise that does not have equal or higher B-BBEE status level, unless the intended sub-contractor is an Exempted Micro Enterprise that has the capability and ability to execute the sub-contract.

b) In relation to a designated sector, the Contractor will not be allowed to sub-contract in such a manner that the local production and content of the overall value is reduced below the stipulated minimum threshold (Percentage of the specific contract).

c) The Contractor does not subcontracting with his subsidiary companies as this may be interpreted as subcontracting with himself and / or using their subsidiaries for fronting. Where the Contractor subcontracts with a subsidiary this must be declared in tender documents.

4.2.5 Attendance on subcontractors

The sub-contractor attends all meetings which the Contractor attends and all meetings as required by the Employer which requirement is not a compensation event.




4.3 Plant and Materials

4.3.1 QualityRefer to 240-105658000 attached.

4.3.2 Plant & Materials provided “free issue” by the EmployerPlant and Materials issued by the Employer becomes the responsibility of the Contractor post issue there of

pertaining to its identification, traceability and preservation. The following Plant and Materials are “free

issued” to the Contractor:

Fabric filter bags

The Contractor ensures that the fabric filter bags are stored as per the bag manufacturers

specifications.

4.3.3 Contractor’s procurement of Plant and Materials

The Contractor provides suitable storage at site to store Plant and Material, parts and equipment. The

storage is water tight and the Plant and Material, parts and equipment is sealed to prevent damage from

moisture and dust. In general the warrantee is one year from delivery.

Where specified, the Contractor follows the storage instructions of the suppliers/vendors/OEM’s or

instructions of the Works Information.

4.3.3.1 Shipping requirements

The Contractor ships all Plant and Material with a description of the equipment or Plant and Material being

shipped, the AKZ numbering, weights, contract number, date and Project Managers name.

The Contractor supplies all handling and lifting Equipment necessary to safely load the Plant and Material

without damage to the Plant and Material. The Contractor supplies temporary ship bracing and tie-downs as

needed to safely transport the Plant and Material to Site.

The Contractor ensures that the following shipping requirements are met.

4.3.3.1.1 FFP Cages

Shipping Requirements

The Contractor ensures that the following requirements are met with regards to the fabric filter bag cages.

A typical shipping and storage crate for fabric filter bag cages can be seen in drawing B0072338J. The

material of construction (wood) is of adequate heft to provide the strength needed to protect the fabric filter

cages during transportation. A minimum of 50 mm x 100 mm or larger wood is used to frame the main

structure. Connections are achieved by both nailing and the use of screws. The ends are braced with a

minimum 50 mm x 100 mm diagonal and webbing or alternate end caps are provided to prevent the cages

from dislodging during transport.

The fabric filter bag cage crate is assembled with dual support levels. This is so the bottom fabric filter cages

are not damaged from supporting the weight of the stack.




The fabric filter bag cage crate is covered with some form of durable cover suitable for both shipment and

storage. Protective covering require UV inhibitors depending upon site storage conditions and schedule.

Fabric filter bag cage crates are capable of being lifted via standard fork lift from the side and from the ends

with extended forks without damage to the fabric filter bag cage crate. The fabric filter bag cage crate bottom

is dual layered to allow for unobstructed inserting of fork lift blades between the two layers.

Provision is made for the lifting of the fabric filter bag cages crates, using the FFP jib crane, to tube sheet

level for installation.

The Contractor includes handling instructions with each bundle of fabric filter bag cages showing full loading,

unloading and storage requirements. The weight of shipping units does not exceed 900 kg.

The Contractor furnishes and sends 4 fabric filter bag cages to the Project Manager for fitting in the fabric

filter bags. The Project Manager must inspect and accept the fabric filter bag cages prior to shipment to the

bag manufacturer. The date for shipping to bag manufacturer will be determined later.

4.3.3.1.2 Damper

Shipping requirements

The Contractor ensures that the shipping of dampers follows the damper suppliers Quality Control Plan.

Refer to Appendix B for all shipping information required from the Contractor.

4.3.3.1.3 Pipe spool

Shipping requirements

The Contractor ensures that each shipment includes identifying marks consisting in addition to the contract

number and the Project Managers name as per shop sketches and clearly marked on all pipe spools.

Pipe spools are marked with white indelible lead free paint in a readily visible location with minimum 50 mm

high lettering.

See Employer pipe specification for further information.

4.3.3.1.4 Pipe

Supports Marking, Tagging and Packaging and Shippimg

The Contractor ensures that each pipe support assembly has a unique Pipe Support Tag Number (ex PS-U3-

001).

Each pipe support assembly has multiple loose parts (hardware & field welded items). Each loose part is

marked with the pipe support tag number / banded / “packaged” together, by the Contractor, as one for

shipping (in case they are ever separated from the package.).

Each pipe support package is tagged with the following:

Employer Contract Number

Pipe Support Tag Number

Date




4.3.3.1.5 Pulse Air

Headers Shipping Requirements

The Contractor submits a recommend packaging plan complete with drawings or sketches prior to shipment

to the Project Manager for acceptance. The headers require particular attention to prevent damage. Protection

of the headers and attached components using plywood boxing and plastic sheeting is required. All

openings are plugged or have plastic covers taped in place.

4.3.3.1.6 Blow pipes

and J pipes Marking, Tagging and Packaging




The Contractor marks all ship unit assemblies with white indelible paint in a readily visible location with

minimum 50 mm high lettering, with the following information:

Employer Contract Number

Ship Unit Number

Ship Unit Name

Ship unit weight, in kilograms

AKZ Code or description where an AKZ code is not available.

Project Managers name

Small parts, such as bolts, nuts, and washers, are packaged and tagged, by the Contractor, with the

information defined above and quantities indicated.

Blowpipes may be bundled together (properly supported to protect flanges) for shipping and the bundle

marked as discussed above.

All Blowpipe / J pipe / Extension pipe open ends are protected or sealed during shipment (plastic pipe cap),

by the Contractor. Blowpipes are bundled such that the small blow holes are pointing down during shipment

and storage.

Any temporary shipping bracing, ties, or erection bolts, are painted YELLOW to indicate that the attachment

is to be removed after completion of field erection.

J pipe assemblies / Extension pipes can be stacked 3 or 4 high for truck shipments if deemed a safe load &

properly supported, by the Contractor.

4.3.3.1.7 Tube sheet

Marking, Tagging and Packaging

The Contractor utilizes tube sheet packaging adequate to ensure the tube sheets arrives at Site in good

condition, refer to Section 6.4.7. Packaging is of particular concern to locations requiring shipment on




coastal jobsite locations and for ocean or coastal inland waterway shipment. The Contractor submits the

intended packaging means to the Project Manager for acceptance prior to shipping.

The Contractor avoids using any tube sheet holes as tie downs of the tube sheets as damage to the hole

edge can occur. Any shipping frame used, by the Contractor, to stack tube sheets are accepted by the

Project Manager before stacking and shipping.

Ship-unit assemblies are marked with white indelible paint in a readily visible location with minimum 50 mm

high lettering, where possible, with the following information:

The ship unit mark number is as indicated on the DEA drawing ship unit number index.

Employer Contract Number.

Relevant AKZ Code.

Shipping-unit weight, in Kg.

The Contractor packages and tags small parts, such as bolts, nuts, and washers, with the information defined

above. In addition, the quantities of each part in the package are indicated.

Find markings and Datum lines are clearly marked and identified, by the Contractor, per the design

drawings.

The Contractor ensures that all temporary attachments such as shipping bracing, ties, or erection bolts, are

painted YELLOW to indicate that the attachment is to be removed after completion of field erection.

The Contractor attaches the storage & handling procedures to each tube sheet assembly.

4.3.4 Spares and consumables

The Contractor supplies the Employer with a detailed complete list of all spares required for start-up,

commissioning and operation in order to maintain the works for the first two years of operation. This list of

spares is supplied with the Enquiry documents. Spares are to be available for purchase in South Africa.

The Contractor supplies a list of recommended critical and normal spares as per the VDSS in Appendix B.

The recommended critical spares lists is for normal operation for mechanical, process control, C&I and

electrical components required to maintain the works between GOs (six (6) years). Included in the list is the

description of the individual spares, type, part ordering number and supplier information.

The spares list includes the following:

Price, valid for six (6) months

Component reference number

Component description

Guaranteed supply period before component becomes obsolete




Mean time between failure (MTBF) of components/parts

Mean time to repair (MTTR)

Order lead time

Criticality (low, medium or high)

Indication of the availability of local support for components

The Contractor assists the Employer to determine which spares (for the entire works) are to be kept as stock

items in the Employers stores.

All similar items for the works and all similar consumables are interchangeable with each other, these results

in the spares stock holding being minimised. Where it is possible, components such as motors are designed

to reduce the number of equipment variation.

The Contractor provides spares for start-up, commissioning and the first two years of operation. The

Contractor provides the spares as indicated on the equipment data sheets, where applicable. The Contractor

in addition provides the spares as described in the Works Information and in this section below.


The Contractor supplies 5% spare fabric filter bag cages per Unit. The spares are provided in the shipping

filter bag cage crates, refer Section 4.3.3.1.1, and are stored by the Contractor in the site workshop.

The Contractor ensures that the fabric filter bag cages of the next FFP unit to be constructed are onsite

before installation of the first FFP units fabric filter bag cages.

4.3.4.2 Instrumentation

The Contractor supplies an individually priced spare parts list (including pricing, expected delivery and

weight of each part) for critical spare parts and consumables for start-up/commissioning and for one (1) year

of normal operation. This is completed and returned with the Enquiry documents.

The Contractor provides spare parts, consumables and special tools, and ensures that they are properly

boxed for shipment with contents identified. Parts are suitably protected from moisture for long term storage,

and is boxed separate from the original equipment supply.

4.4 Tests and inspections before delivery

The Contractor ensures that the tests and inspections as listed in this section are carried out as minimum.

The Contractor ensures that proof of inspections and the outcome of the inspections are documented and

available to the Project Manager when requested.

The Contractor’s ensures that his inspector has authority to stop fabrication and initiate corrective actions

when non-compliance is discovered. No shipment is made until the inspector has certified that the

components comply with this specification.




4.4.1 FFP Cages Inspection Criteria

At a minimum the fabric filter bag cages are inspected, by the Contractor, for the following:

Dimensions within tolerances, including cage diameter and overall length.

Integrity, fit and suitability of the coupling connections (check fit-up to confirm no movement between

mating pieces).

Collar dimensions and square of collar to the cage (per Drawing B0222864).

Hem cup dimensions (per Drawing B0222864).

Cage straightness and verticality in the hung position.

Check bow of mating cage pieces both before and after assembly to ensure no change (permanent

deformation of the cage).

Completeness and integrity of welds (particularly welds between wires and collar).

Absence of sharp edges and burrs.

Inspections are conducted, by the Contractor, at the following minimum intervals:

Dimensional tolerances listed (per Drawing B0222864) are checked at the beginning and periodically

throughout the assembly process (1 sample per 25 cages for the first hundred cages, and one cage

for every 100 cages thereafter).

Spot-check welding throughout the manufacturing process as required.

Assemble and check cage straightness of the assembled fabric filter bag cages one cage per 25

cages for the first hundred cages and one cage for every 100 to 250 cages thereafter (the

appropriate frequency to be determined by the Supervisor).

The check is performed as follow;

Suspend cage from level 'parallel' bars or a level simulated tube sheet in Contractor’s shop. Measure

offset of bottom of cage from a laser beam or alternate accurate means to establish 'absolutely

vertical' relative to the centre of the tube sheet hole(s) or from a plumb bob line if conditions allow

adequate measurement precision with this method.

The assembly of the cage is of random orientation. There is no bias to cage straightness and no straightening of the assembled cage.

Filter bag cages after assembly are straight with a maximum bow of (12 mm). The test procedure is

to place a vertical reference at the cage top and bottom using a laser or string line set (25 mm) from

the cage OD. The cage is rotated (in steps of 90 degrees – 4 measurements) with the minimum

distance of any point along the cage length not closer than (12 mm) to the laser / string line.

Cages are rotated 360o and achieve plumbness at all positions.

Sharp edges/burs are spot-checked throughout the manufacturing process.

4.4.2 Poppet dampers (FFP Outlet and Implosion Dampers)

As a minimum, prior to shipment, the Contractor cycle tests the dampers in order to inspect the drive train

components and bearings for signs of binding or over stress. Other testing may be required per the Project




Managers instruction or Contractor’s QA plan. The Contractor informs the Project Manager prior to testing

and shipment such that the Supervisor can witness the tests. The Contractor provides the cycle test results

to the Project Manager.

As a minimum the Contractor performs the following checks;

Each damper is operated open-close a minimum of five times.

Opening/closing times are checked to verify the times are within the allowable limits specified on the

Data sheet Appendix H.

The blades, seals and drive train components (linkage, bearings, etc.) are inspected for evidence of

binding or undue stress.

A written test report, listing the test results, is issued by the damper Contractor.

Standard testing is performed prior to shipment. Standard testing includes cycle testing of the

operators and gap verification of the seals, standard visual and dimensional testing of all Plant and

Material.

4.4.3 Blow pipes and J pipes

The Contractor ensures that his appointed inspector has authority to stop fabrication and initiate corrective

actions when non-compliance is discovered. No shipment is made, by the Contractor, until the inspector has

certified that the components comply with this Works Information.

Visual examination of all welds is in accordance with AWS D1.1.

The Contractor develops inspection sheets and submits to the Employer for acceptance. The following

inspections are to verify tolerances to the Employers drawings.

Verify material specification supplied is in accordance with Employers drawing.

Verify ship unit lengths, widths, and thicknesses.

Verify blowpipe hole locations, and other cutouts with respect to the datum line.

Verify datum lines are perpendicular to each other. See Drawings Verify hole diameter, roundness, free of burrs, taper and locations.

Verify weld size and location per drawing. Quality of welds are as per specified code.

The following is the recommended minimal frequency of special inspection and verification during fabrication:

Table 2 : Minimum Frequency of Inspection for J pipes and Blow Pipes

Description Number of tests per pieceQA record

within signoff required

Number of pieces tested.

C/L of J-pipe to datum at expansion joint end (vertical)

100% of the J-pipes on the first assembly, 10% of the J- pipes thereafter

Yes 100% Assemblies

C/L of J-pipe to datum at blowpipe attachment flange end (horizontal)

100% of J-pipes on first assembly, 25% thereafter

Yes 100% Assemblies




J-pipe channel camber 1 Yes 100%

J-pipe channel attachment bolt

levelness

100% Yes 100%

Blowpipe – Angularity of blowholes & dimensions.

100% on first blowpipe, 10% thereafter

Yes First 5 then every 5th

4.4.4 Tube sheet

The following inspections are done in the shop, by the Contractor, to verify tolerances to Design drawings in

Appendix K.

Verify material specification supplied in accordance with drawing.

Verify length, width, and thickness of tube sheet.

Verify hole locations, and other cutouts with respect to the datum line.

Verify datum lines are perpendicular to each other.

Verify hole diameter, roundness, taper and locations.

Verify hole surface (inside diameter) meets a surface finish of RMS 125 maximum. Imperfections do

not exceed 0.076 mm in depth.

Holes are free of burrs. The holes and top of tube sheets are free of weld spatter. Weld spatter is a

minimum of 6 mm from the hole edge on the tube sheet bottom (Stiffener side).

Verify flatness in each direction using Rock-No-Rock, no rock gauge.

Verify the material and location of stiffeners.

Verify fillet weld size and location per drawing. Quality of welds is as per AWS and free of cracks.

Verify tube sheet splice welds are a minimum of 25 mm from tube sheet holes.

Lifting rig inspections includes adherence to the drawing requirements.

The Contractor ensures that his inspector has authority to stop fabrication and initiate corrective actions

when non-compliance is discovered. No shipment is made until the Contractor has certified that the

components comply with this specification. The Contractor provides proof of the inspection to the Project

Manager.

4.4.5 Louver Dampers (FFP Compartment Inlet Dampers)

The Contractor ensures that, as a minimum, prior to shipment, the dampers are cycle tested in order to

inspect the drive train components and bearings for signs of binding or over stress. Other testing may be

required per the Employer’s specification or Contractor’s QA plan.

Each damper is operated open-close a minimum of five times.

Opening/closing times are checked to verify the times are within the allowable limits specified in the

Works Information.

The blades, seals and drive train components (linkage, bearings, etc.) are inspected for evidence of

binding or undue stress.




A written test report, listing the test results, is issued by the damper manufacturer to the Contractor

and supplied to the Supervisor

Manufacturer’s standard testing is performed prior to shipment. Standard testing includes cycle

testing of the operators and gap verification of the seals, standard visual and dimensional testing of

all manufacturers’ products applies.

The Contractor informs the Supervisor at least seven (7) days prior to performing final inspection and testing

of damper equipment and 21 days if it’s abroad before dampers are ready for shipment unless otherwise

noted per owner requirements. The Supervisor then has the option to view and be present at the test or

review the test results.

4.4.6 Valves

All automated valves are given shop operational tests to verify proper operation of the valve, the actuator

and its accessories.

The Contractor prior to shipment strokes all valve operators with adjustable mechanical stops and set the

mechanical stops to ensure proper operation of the valve.

4.4.7 Actuators

The Contractor performs actuator bench tests and functional tests to verify proper operation of the actuator


The Contractor informs the Project Manager prior to testing and shipment such that the Supervisor can

witness the tests.

The Contractor provides test certificates and inspection records to the Project Manager prior to delivery to

Site.

4.4.8 Pulse Air Headers

The following inspections are carried out by the Contractor to verify tolerances to the Contractors

manufacturing drawings;

o Verify material specification supplied is in accordance with Works Information

o Verify length, width, and thickness

o Verify hole locations, and other cut-outs with respect to the datum line.

o Verify hole free of burrs, taper and locations

o Verify weld size and location per drawing. Quality of welds are as per specified code

o Verify all fittings and electrical connections are per drawing requirements

The following is the recommended minimal frequency of inspection and verification during fabrication:




Table 3 : Pulse Air Header Inspection Frequency

Description Number of tests per piece QA record withinsignoff required

Number

of pieces

tested.

Headers –discharge pipe to datum

100% of the discharge pipes on first header,

10% of the discharge pipes thereafter

Yes 100% of the

headers

Verify airconsumption

Perform air consumption guarantee per

section 4.1

Yes First Header

Sequenceroperation

Verify operation of all valves in the specified

sequence. This can be done without

pressurizing the header.

Yes 100%

Inspect tubing(if installed)

Inspect valve supply tubing, any flattening,

kinking or wrinkling of the tubing shall be

rejected and reworked.

Yes (if header has

tubing)

100%

4.4.9 Pre Factory Acceptance Test

The Contractor is to conduct a pre-factory acceptance test at the Contractor’s factory in preparation for the

FAT. The Contractor completely tests and verifies the performance of the Plant and Equipment against the

requirements and the detailed engineering design freeze.

The Contractor’s Pre-FAT tests are documented as part of the Contractor’s QC procedure. The Contractor

submits the QC procedures and Pre-FAT test and inspection results to the Supervisor prior to the

commencement of FAT.

4.4.10 Factory Acceptance Test (FAT)

The approved FAT procedure is done at the Contractors manufacturing factory. During FAT, the Contractor

demonstrates that the system meets the requirements of and the detailed engineering design freeze

documentation. The Contractor, OEM and the Supervisor witness verifies and documents the FAT. This is

included on the ITP/QCP and documented in the data book.

Cleaning air equipment plant system (e.g. Compressors and driers) controllers/PLC’s requires a FAT.

All Electrical Plant and Material are to be subject to routine tests, as part of FAT, as specified in the

applicable standards (see Section 6.3). Electrical Plant and Material that does not have type test reports and

certificates for the same type are to be subjected to type tests as per the applicable standards specified in




Section 6.3. All Electrical Plant and material testing is to be conducted as per the documentation specified in

the VDSS in Appendix B.

New pre-wired DCS cubicles, panels, PSU panels, and sequencer panels are tested and inspected before

delivery to site. The Contractor informs the Project Manager prior to testing and shipment such that the

Project Manager can witness the tests.

A documented FAT Procedure is to be submitted to the Employer for acceptance and is recorded on the

ITP/QCP and documented in the data book before any testing is done.

4.5 Marking Plant and Materials outside the Working Areas

In addition to the information required when shipping the Plant and Material, the Contractor marks all Plant

and Material with the following information while outside the working areas and ensures that the information

is accurate and clear/readable;

Project Manager name

Contract name

Contract number

AKZ code and description

Plant and Material description if AKZ number is not applicable

Refer to Section 4.3.3 for marking outside of the Working Areas and during shipping.

4.6 Contractor’s Equipment (including temporary works).

Refer to section 3.5.




5 Construction

The Contractor is responsible for demolition, supply of Plant and Material, fabrication, handling, shipping,

storage, delivery and erection/construction of structural steel, miscellaneous support steel (including pipe

racks and pipe supports), access platforms, staircases, ductwork, foundations, Equipment, spares required

to supply the works. The Contractor is responsible to construct any works that can be reasonably inferred

from this Works Information and the Employer’s drawings, refer to Appendix J.

The construction of the civil/structural works is in accordance to the relevant sections of the SANS 1200,

SANS 1400 and SANS 2001 series standardised specifications.

5.1 Temporary works, Site services and constructions constraints

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

Access to the site will be via the two main security gates only (East and West gates). The Employer informs the Contractor of the access procedures and the Contractor should expect that such procedures might change depending on the prevailing security situation. The Contractor recognises and ensures that his price and programme is fully inclusive of delays that could be experienced as a result of the following or any other delay related to site access and departure:

Delays at the security gate. All Contractors are required to provide proof of medical screening and Man job specification

before Employer’s induction is granted. Induction is only conducted after the safety file has been approved. The Employer reserves the right for verification and confirmation of the local unskilled and semi-

skilled labourers, and may stop the induction process if found to be in breach of local to site recruitment.

The Employer reserves the right for its Security personnel to search persons or vehicles entering or leaving the premises. This includes briefcases, laptops and toolboxes.

The Employer refuses access to Site for reasons such as security concerns; disorderly conduct, substance abuse, misconduct, criminal records. The Contractor is not entitled to a change in Prices, Key Dates and/or Completion Date as a result of this.

a) Temporary Gate Permits The Contractor is expected to provide the Employer with the personal details of their staff at least

two working days prior to the occupation date. All names and details to be submitted to the Project Manager or his appointed representative who

arranges for all gate permits which is only sanctioned after medical screening of individual employees are completed and records submitted.

Lost permits will be paid by the Contractor to the Protective Services at a cost that will be charged by the Employer per lost permit.

The Contractor ensures that all its employees and sub-contractors carry their access cards at all times.The Contractor obtains a “Gate Permit” from the Employer before materials and equipment can be removed from site. A “Gate permit” gives an itemised list of materials and equipment to be removed from site.

b) Routine Prohibitive Substance Testing

The Employer conducts standard routine prohibitive substance testing on all employees and Contractors which could result in the immediate removal and suspension of such parties from Site. Delays through the




gate can be experienced as a result. Such events do not construe a change to the programme, an extension of time or a cost recovery event.

5.1.1.1 Construction considerations

During the erection period, the Contractor as a builder and/or user of machinery performs 'building work' in

terms of OHS Act. The Contractor, before taking occupation on a Site, obtains a 'Contractor’s Possession

Certificate' from the Project Manager. Before a part of the Site is released for access to Others, the said part

conforms to the safety requirements of OHS Act. The party taking access then becomes the 'User' in terms

of OHS Act. The releasing of a part of the Site in the above described manner does not relieve the

'Contractor Giving Access' of any of his obligations in terms of his contract with the Employer. No

unauthorised person(s) enters into any prohibited/restricted area. Daily diaries/logs are kept by the

Contractor and signed off daily by the Supervisor The following is to be recorded on the daily diaries:

Manpower and Equipment used

Weather conditions

Any unique occurrences

Industrial relations abnormalities

Interface and access problems

In addition to the aforementioned, the Contractor adheres to the following:

The Contractor is restricted to the Site.

The Contractor is not to enter any other areas and ensures that his employees abide by these regulations.

The Contractor performs all hoisting and lifting, by qualified riggers.

The Contractor’s Equipment does not impair the operation or access to the plant.

The Contractor provides any temporary or expendable materials required for the storage of material.

The Contractor safeguards and secures all items whilst in the Contractor's custody and control, until completion of the whole of the works.

All cutting of pressure parts is done with pneumatic grinders only.

The adjacent plant and equipment are not modified without written permission from the Project Manager. Modification in this sense includes, but is not limited to the following:

o Welding onto existing plant

o Cutting into existing pipework

o Drilling into civil structures




5.1.1.2 Work Method Statement

The Contractor provides a detailed work Method Statement for each activity of his work, together with activity

durations. In addition to a description of the method of constructing the works, the Contractor, in his work

Method Statement, includes the following as a minimum:

The scope of the particular Method Statement

A comprehensive description of the activity

How the Contractor has taken into account the constraints for constructing the works, including those

listed in Section 5.1.17.3.

A clear description of the responsibilities of the Contractor’s personnel involved in the activity,

including (where applicable) his Project Manager, Site Quality Manager, Site Engineer, Health and

Safety Manager, Technical Office Manager, Production Manager, Supervisor, Environmental Officer

and other personnel required for the activity work.

Reference to applicable statutory requirements and how the requirements have been taken into

account.

Health, safety and quality control for the activity.

All plant and machinery required to complete activity.

Quality control points as accepted by the Project Manager.

Welding procedure specification for the activity.

All work Method Statements include the name and qualification of the personnel working in the specified

activity in conjunction with the requirements as set out in 240-105658000. All Method Statements are

accepted by Project Manager prior to starting any work.

5.1.1.3 Detailed Construction Work Method Statement

As a tender returnable, the Contractor submits a Detailed Construction Work Method Statement taking into

consideration the various phases of the project and demolition activities. This method statement clearly

illustrates how the Contractor accounts for the risks of this project, including the risk of not completing the

construction within the outage duration. This method statement is tailored to address the specified project

objectives and requirements. This method statement adequately deals with the critical characteristics of the

project.

The Detailed Construction Work Method Statement includes, at minimum, the following:

Constraints identified and considered by the Contractor.

Interfacing with Others, the Contractor illustrates an understanding of the work that is to be

completed by Others and accommodates for the completion of such work in his methodology.

Description and illustrations of a construction traffic plan, use of laydown areas and plot plan.

Shifts and hand overs for the various sections of the works, this information is to enable the

Employer to integrate the programmes of the various contractors.

Design tools and systems that the Contractor plans to use.




Detailed risk assessment which lists risks specific to the works and is accompanied with associated

proposed mitigations.

List and description of plant and machinery required to carry out the civil and structural components

of the works.

Inspection and quality control plan.

A clear description of the responsibilities of the Contractor’s personnel involved with the works,

including (where applicable) his Project Manager, Site Quality Manager, Site Engineer, Health and

Safety Manager, Technical Office Manager, Production Manager, Supervisor, Environmental Officer,

Fabricator, Erection Engineer, Shop detailer, Transporter and other personnel required for the civil

and structural works.

Construction sequencing considerations (not limited to steel works) which take into account the

constraints as indicated in this Works Information.

The Contractor takes into consideration in his construction programme, the C&I scope that can only

commence when the Unit is on Outage.

An investigation into the possibility of carrying out work prior to the outage. This investigation clearly

defines all activities which can be carried out prior to outage (if any) and is reflected accordingly in

the Construction Programme, refer to Section 5.1.1.4.

A concrete works method statement which describes the following as a minimum:

o Concrete sourcing

o Testing facilities

o Testing procedures

o Concrete placing and curing

A steel works method statement which describes the following as a minimum:

o Corrosion protection and painting

o Method of fabrication and erection

o The physical location of manufacturing and fabrication

o Erection procedures which includes considerations for modularisation and construction

sequencing, including a lifting and rigging plan

o Welding procedures that the Contractor plans to use

o Steel transportation

An earthworks method statement which describes the following as a minimum:

o Excavation procedure

The Contractor submits a new Detailed Construction Work Method Statement, a month prior to commencing

with any construction activities, which covers all the aspects listed above and any additional requirements or

changes arising from negotiations or clarifications, for acceptance by the Project Manager. This Method

Statement is to include interfaces with Others. This new method statement includes a sequential erection

procedure which clearly shows detailed consideration for stability requirements of the structure at all stages

during erection and a constructability analysis which includes the following:




An analysis of the access to Site.

An analysis of the crane usage requirements, crane locations and possible congestion to traffic.

An analysis of the excavations required for the ID fan support structure and associated possible

impacts on the delivery of the works.

5.1.1.4 Construction programme

As part of the Detailed Construction Work Method Statement and as a tender returnable, the Contractor

submits a Level 3 construction programme that considers all the interfaces and time constraints. This

programme does not omit key activities. Timing of the activities is consistent with the Detailed Construction

Work Method Statement (refer to Section 5.1.1.3). This programme is accompanied with the following:

A comprehensive narrative which describes the basis of the schedule.

A list of assumptions that the schedule was based on.

The programme clearly indicates the following:

The amount of shifts planned per day for each section of the works.

The way in which the Contractor plans to interface with Others. Interface points with Others are

identified in the programme.

The critical path.

A comprehensive description of each activity, including the name and designation of the responsible

person.

The programme is to show that the Contractor has a clear understanding of the full scope of works, including

the accompanying risks. The programme is to be logical and realistic. For additional project programming

requirements, refer to Section 2.6.

5.1.1.5 Temporary works

The Contractor designs and constructs all temporary works required for the construction of the works. The

Contractor dismantles/demolishes temporary works when such works are no longer required.

5.1.1.5.1 Tower crane foundations

The Contractor designs and constructs the tower crane foundations. After the construction of the works for

each unit, upon a time agreed with the Project Manager, the tower crane foundations are demolished,

removed and disposed from Site. The Contractor submits the tower crane foundation design and structural

drawings to the Project Manager for acceptance. The location of the tower crane is such that access to the

various working areas is maintained.

The Contractor completes the construction of the tower crane foundations prior to outage.

The Contractor is responsible to assess if the demolished foundations are contaminated. The foundations

are disposed of in the appropriate disposal site if the foundations are contaminated, by the Contractor. Any

damage caused to the ground slab is made good, by the Contractor.




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

Restrictions and hours of work will apply at the Tutuka Power Station. The Contractor keeps records of his employees on Site, including those of his Subcontractors which the Project Manager or Supervisor has access to at any time. These records may be required by the Employer at any given time for the following but not limited to:

a) Emergency (evacuation/drill) and investigations

b) Labour unrest

c) Absenteeism

d) Sick leave

e) Assessments (labour hours timesheets)

5.1.3 Health and safety facilities on Site

The Contractor provides a First Aid service and SHE representative to his employees and sub-contractors. In the case where these prove to be inadequate, like in the event of a serious injury, the Employer’s Medical Centre and facilities will be available. Outside the Employer’s office hours, the Employer’s First Aid Services are only available for serious injuries and life threatening situations.

5.1.4 Title to materials from demolition and excavation

The Contractor has no title to materials from excavation and demolition (e. g. copper). The Contractor

notifies the Project Manager when such materials are found and the Project Manager instructs the Contractor

how to deal with such materials. In circumstances where certain equipment is required for spares, the Project

Manager gives special instruction detailing a specific storage area and identifying which parts to be stripped.

The Contractor is responsible for disposal of all the waste generated from the works in an environmentally

friendly manner, ensuring that hazardous (contaminated rubble) and general waste are disposed of at a

nearest registered landfill site. The Project Manager needs to be notified of the disposal site before any

disposal can be done. For all scrap metal, cables and material the Contractor submits with the tender the

price per tonne for disposal of such material. In case of salvaged equipment, identified by the Project

Manager, the Contractor is expected to safely remove such equipment and store it at the designated site as

identified by the Project Manager. The list of all salvaged equipment is to be issued to the Contractor before

the start of the works.

5.1.5 Cooperating with and obtaining acceptance of Others

There will at times be Others working in the same area as the Contractor, it is the responsibility of the Contractor to co-ordinate his work with the Employer and Others to maintain harmonious working conditions on Site.

During the progress of the works the Contractor provides access to Others who also execute work in the same area, as and when required and agreed with by the Employer.

The Contractor makes his own assessment of the challenges which may be encountered for providing access to and interfacing with Others (this includes access difficulties experienced during construction or




commissioning phase). Where there are difficulties or unresolved interfacing or access issues the Contractor must ensure that they meet with Others to find solutions or resolve issues without impacting his/her execution of the works. The Contractor is not entitled to a change in Prices, Key Dates and/or Completion Date as a result of the interface obligations or the Contractor’s assessment.

If the Contractor and Others are unable to resolve the problem, they will meet with the Employer in order to find a solution or resolve the issue. The Employer will issue an instruction to the Contractor and Others on how to proceed.

5.1.6 Publicity and progress photographs

The taking of photographs at the Power Station including the Project Works is restricted and subject to the

approval by the Project Manager.

For the purpose of the Progress Reporting Requirements, the Project Manager may prohibit the taking of

such photographs and/or require that all such photographs be taken by an official Employer photographer. In

the latter event, the Contractor is required to make arrangements directly with the photographer for the taking

of the photographs required by the Contractor for the purpose of the Progress Reporting Requirements.

All publications on site must not contradict Eskom regulations and publication legislation in general.

5.1.7 Contractor’s Equipment

a) The Contractor’s Equipment does not impair the operation or access to the plant.

b) The Contractor provides all or any temporary and expendable materials required for the storage of material.

c) The Contractor provides a list of all Equipment on Site whether it is owned or hired, for record purposes.

d) The Contractor ensures that all his equipment on site including scaffolding has unique identification Note : For any removal of equipment from site, refer to section 5.1.1

5.1.8 Existing premises, inspection of adjoining properties and checking work of Others

Where the Contractor requires to work in the same area as Others either at the same time or consequentially or there is interface with Others either at the same time or consequentially (“the Overlap”), the Contractor notifies the Employer and Others. The Contractor includes the Overlap in his programme and ensures Others also include it in their programmes. The Contractor’s programme will be rejected in accordance with clause 31.3 of the NEC if he fails to do so.

The Contractor notifies the Employer and Others a minimum of [two] calendar weeks before the Overlap starts. The Contractor inspects the Overlap area on the day he is to start work, liaises with Others and completes a report on the Overlap area and the works in the Overlap area. He submits to the Employer within [48] hours of the date of starting work. The Contractor who requires access is responsible for compiling the report. His report includes the adequacy of the Overlap area, the works in the Overlap area; damage to the Works, a record of Others working in the Overlap area and any Other constraints in the area. The Others working in the Overlap area also sign the report. The Contractor does the same when he completes the work in the Overlap area. The Contractor promptly notifies the Employer of any damage to his works or any other part of the Overlap area on both starting and completing his works and provides an




explanation of how the damage occurred. The Contractor caters for the time for this activity in his revised programme for acceptance to ensure that there is no delay on his part.

The Contractor identifies all interfaces with others in his Contractor’s Works Information and as required by paragraph 2.6 of this Works Information and does so for the execution of the Works. The Contractor inspects the works of Others whom he has identified as an interface point and where alignment and compatibility between the Works and Others’ works is required. Similarly, the Contractor also allows Others to inspect his works as required by them.

5.1.9 Construction Sequencing Video and Mock-up

The Contractor creates an animation video which clearly shows the construction sequencing of the various

parts of the works for the FFP. The outcome of this video is such that it aids in evaluating the constructability

of designs, it contributes to an understanding of how the Contractor plans to construct the works and serves

as a tool with which the construction execution can be optimised. This video does not omit any components

which form part of the sequence of executing the works, including demolition and dismantling. The video

clearly shows how the construction of the FFP is modularised.

The Contractor demonstrates a mock-up erection of the FFP modularised sections in the Site Construction

Workshop. Both the mock-up erection and the video only consider the FFP and exclude the Site

Construction Workshop.

This video and mock-up erection is submitted to the Project Manager for his acceptance. The video is

handed over to the Employer; after hand over the rights, title and interest in the video vests with the

Employer. The video and the mock-up erection are considered part of the works and becomes the property

of the Employer upon submission.

5.1.9.1 Demolition and dismantling

The Contractor complies with the requirements of the Construction Regulations. All rubble is removed from

Site by the Contractor and disposed of at the designated site without delay; the location of disposal is agreed

upon with the Project Manager. Mechanical demolition is preferred. Full details of the civil demolition

procedures and methods are provided to the Project Manager for acceptance.

Sections of the existing electrostatic precipitator (ESP) are dismantled by the Contractor in accordance the

Employer’s design and the Contractor’s method statement. The section to be dismantled are indicated on

the Employer’s drawings, refer to document 360-1223, and as can be reasonably inferred by the Employer’s

design. The method of demoltion and dismantling these sections is the reponsibility of the Contractor. The

Contractor creates an animation video which clearly shows the dismantling and demolition sequencing of the

various parts of the works for the ESP, refer to Section 5.1.9.

The Contractor develops a demolition and dismantling method statement complete with drawings clearly

indicating the various demolition phases. This demolition method statement is submitted to the Project





The existing ESP longintudinal walls (side walls) are re-used as part of the FFP construction. The Contractor

does not damage the existing longitudinal walls. The Contractor has a option to submits an alternative

solution for removing the longitudinal walls as per Section 3.1.1.7.1. The Contractor clearly shows all risks

and schedule impacts.

5.1.9.2 Vent pipe removal

The Contractor is responsible for removal and reinstallation of the vent pipe on top of the ash bunker.

Connections to both the FFP inlet ducting and the ash bunker, all fasteners and gaskets, as well as the

installation and removal of the gaskets and fasteners is the responsibility of Others. Refer to marked up

drawings of 0.61/7738, 0.61/21138 and 0.61/7782.

5.1.9.3 Bucket Elevator removal

The Contractor is responsible for the dismantling and removal of the bucket elevators, the bucket elevator

support structures and all crawl beams on the roof of the ash bunkers. The Contractor is not responsible for

removing any item that needs to be removed from the ash bunker roof that is not connected to the bucket

elevator support structures or crawl beams on the top of the ash bunker (e.g. cables and cable racking), this

is the responsibility of Others. Others are responsible for the disconnection of the bucket elevators from the

transfer ash chain conveyors.

The Contractor is responsible for the cutting and removal of the concrete bucket elevator supports on the

side of the ash bunker such that they do not interfere with the walkways installed for the works.

5.1.9.4 Site Construction Workshop

The Site Construction Workshop is constructed and completed prior to the outage. Prior to handover of the

building to the Employer, the Contractor repairs all defects. This building is only handed over to the

Employer after the Contractor has completed the works. The Contractor’s design engineer, refer to Section

3.2.10, in his final inspection of the completed structure in accordance with the National Building

Regulations, including the health and safety aspects of the structure as far as reasonably practicable,

declares the structure safe for use and issues a completion certificate to the Employer.

Refer to Section 3.2.10 for Site Construction Workshop design requirements.

5.1.9.5 Pulse air receiver tank bases

The Contractor constructs pulse air receiver tank bases as per his design for the case where the Contractor

indicates to the Project Manager that the existing ground slab is inadequate to carry the pulse air receiver

tanks (refer to Section 3.2.12).

The Contractor carries out work, as much as feasible, prior to the outage. The work to be carried out, prior to

outage, is detailed in a work method statement, by the Contractor and submitted to the Project Manager for

acceptance, prior starting the work.




The ID fan is to be upgraded by Others. It is for this reason that the Contractor prioritises construction

activities at the ESP outlet area to allow for Others to commence with their work. Therefore, as soon as the

Employer has declassified the ESP, the Contractor prioritises the following activities:

5.1.9.6 Removal of the ESP outlet flue Equipment provided by the Employer

No equipment is made available for the Contractor’s use by the Employer.

5.1.10 Excavations and associated water control

No excavations are permitted, by the Contractor, without first obtaining an excavation permit. The Contractor

complies with the requirements of the Construction Regulations. Excavations are performed such that it

imposes a minimum restriction on access to Site for Others. Excavation permits are only issued if the area

has been scanned, by the Contractor, to ensure that there are no underground services in the area to be

excavated. Refer to Safety, Health & Environmental Specification – GCD/TUT/SHE06.

5.1.11 Site services and facilities

Refer to the Employer`s Specification Safety, Health & Environmental specification, GCD/TUT/SHE06,

revision 1. All services and facilities that are not specifically stated to be provided by the Employer and

which are necessary for Providing the Works are provided by the Contractor.

5.1.11.1 Site Office, Store and Housing

An area will be made available by the Project Manager for the Contractor’s site offices, workshops and stores

5.1.11.2 Telephone Facilities

The Contractor is responsible for arranging his own telephone facilities. Neither network points nor

telephones are available on Site. Should the Contractor require one, he is to make his own arrangements

with relevant authorities. Should the Contractor wish to use radio communication equipment on Site, he will

make his own arrangements with the relevant authorities and ensure that there is no interference with

existing channels or equipment.

5.1.11.3 Ablution Facilities

Ablution facilities are available on some areas on Site. Where there is no ablution facilities the Contractor

makes the necessary arrangement to provide these facilities. Chemical serviced toilets are the minimum

acceptable standard and maintained in a clean and sanitary condition.

The Contractor is to supply own sanitary facilities at his Contractor’s yard.

A refuse control system will be established by the Contractor. All waste and refuse will be collected and

disposed of as directed by the Employer




5.1.11.4 Storage Facilities

The Employer has no roofed storage facilities available for use by the Contractor who must make his own

arrangements in this regard. There will however be a lay down area available on site for the Contractor to

temporarily store construction materials. All storage facilities (Plant, Material and Equipment) will be within

the boundaries of the Site not to affect the operations of Others.

5.1.12 Facilities provided by the Contractor

It is required, for the proper co-ordination and execution of the works that the Contractor establishes an office

on Site for the duration of the contract.

The Contractor includes in his establishment rates for all further treatment of the yard areas that he

considers necessary for his entire operation throughout his period of occupation and under all weather

conditions. The Contractor also includes for all security fencing, security and access arrangements. The yard

will be kept clean and tidy at all times, this will include all workshops and storage areas under the control of

the Contractor. Maintenance of the yard is the Contractors responsibility and is for the Project Managers

acceptance.

Outfall drainage of all surface run-off drains is constructed by the Contractor to the acceptance of the Project

Manager to minimise erosion and to effect control of contaminated water. The Contractor’s plan for the layout

of his yard area are accepted by the Project Manager prior to occupying the yard and the Contractor does

not occupy any site area other than that allocated to him. The Contractor’s plan states fully what measures

are taken regarding removal and storage of topsoil, stabilisation of eroded areas and further loss of topsoil.

The Contractor complies with the environmental policy given in the Site Regulations. The Contractor

provides, erects and maintains for his own use adequate size office accommodation and stores together with

such drainage, lighting, heating, and hot and cold water services as may be required. Provision is also made

for adequate parking and a turning area adjacent to all the aforesaid structures. The Project Manager prior

to commencement of any work on Site accepts all designs and layouts for these provisions.

The Contractor dismantles and clears the yard of all such temporary structures and associated foundations

and infrastructure at the direction of the Project Manager on Completion of the whole of the works. No such

dismantling and clearance work is carried out without prior acceptance from the Project Manager.

It is required, for the proper co-ordination and execution of the works that the Contractor has an office on Site

for the duration of the contract.

The Contractor includes in his establishment rates for all further treatment of the yard areas that he

considers necessary for his entire operation throughout his period of occupation and under all weather

conditions. The Contractor also includes for all security fencing, security and access arrangements. The yard

will be kept clean and tidy at all times, this will include all workshops and storage areas under the control of

the Contractor. Maintenance of the yard is the Contractors responsibility and is for the Project Managers

acceptance.




Outfall drainage of all surface run-off drains is constructed by the Contractor to the acceptance of the Project

Manager to minimise erosion and to effect control of contaminated water. The Contractor’s plan for the layout

of his yard area are accepted by the Project Manager prior to occupying the yard and the Contractor does

not occupy any site area other than that allocated to him. The Contractor’s plan states fully what measures

are taken regarding removal and storage of topsoil, stabilisation of eroded areas and further loss of topsoil.

The Contractor complies with the environmental policy given in the Site Regulations. The Contractor

provides, erects and maintains for his own use adequate size office accommodation and stores together with

such drainage, lighting, heating, and hot and cold water services as may be required. Provision is also made

for adequate parking and a turning area adjacent to all the aforesaid structures. The Supervisor prior to

commencement of any work on Site accepts all designs and layouts for these provisions.

The Contractor dismantles and clears the yard of all such temporary structures and associated foundations

and infrastructure at the direction of the Project Manager on Completion of the whole of the works. No such

dismantling and clearance work is carried out without prior acceptance from the Project Manager.

5.1.12.1 Penthouse roof sheeting

The Contractor is to install roof sheeting for the Penthouse (this is not indicated on the drawings); 0.8mm IBR

profiled roof sheeting with a 300x450x300mm 2mm thick galvanised MS gutter. The Penthouse roof has a

ridge ventilator with 600mm throat installed to the manufacturer’s instructions. The colour of the ridge and

the roof sheeting is to match the existing power station. The Contractor installs downpipes as required for

the expected runoff.

5.1.13 Contractor’s Equipment

The Contractor provides all management, supervision, labour, installation tackle, gear and tools, vehicles,

rigging tackle, consumables, site offices, stores and any other facilities, equipment and cleaning materials

required to Provide the Works.

The Contractor is required to furnish and maintain the necessary tools and Equipment for the Completion of

the works (including but not limited to all manual and power tools, cranes, elevators, lifts, etc.). The

Contractor provides all necessary scaffolding required to Provide the Works

5.1.14 Control of noise, dust, water and waste

Refer to Employer’s specification GCD/TUT/SHE06 section 5.5 Occupational hygiene.

5.1.15 Existing premises, inspection of adjoining properties and checking work of Others

The Contractor, in conjunction with the Project Manager inspects the site prior to possession. Any defects

established during this inspection are listed on the possession certificate. The Contractor is responsible for

any defect or damage to plant not listed on the possession certificate, occurring during installation.




5.1.16 Giving notice of work to be covered up

The Contractor gives 24 hours advance written notification to the Project Manager of work to be covered up;

refer to Employer’s specification GCD/TUT/SHE06.

5.1.17 Hook ups to existing works

All terminal points are defined in Section 1.2.3 and the LOSS diagrams in Appendix C.

5.1.17.1 Working platforms and scaffolding

The Contractor provides all platforms and scaffolding required to complete the works. All steel access

scaffolding is erected in accordance with SANS 10085-1: 2004. The Contractor uses the platforms and

scaffolding only after it has been safety cleared and does not carry out any modifications to the scaffolding

afterwards.

5.1.17.2 Damage to components not forming part of the works

The Contractor repairs any damage he caused to any components which do not form part of the works at his

own cost.

5.1.17.3 Site and time constraints

Site and time constraints include but are not limited to what is listed below. The Contractor, prior to

tendering, becomes aware of all the possible constraints by inspecting the supplied drawings and by

attending the compulsory site visit. The supplied existing site drawings may not be complete therefore it is

necessary for the Contractor to inspect the Site during the site visit. The constraints during construction

include but are not limited to the following:

There is a cable tunnel on both the eastern and western sides of the casing, refer to drawing

0.61/12294 rev 3; this drawing is only provided for information purposes.

New ID fan support structures and foundations will be constructed during the same outage by Others

in the location of the current ID fans, refer to Figure 1.

A new DHP Blower House will be constructed during the same outage period, between the existing

ID fans.

The access way between the existing ESP support structure and outlet flue support structure is

constricted.

The contractors of the various site activities may use the same access simultaneously. Some of the

factors which may limit this access are:

o The construction of the DHP Blower House between the two ID fans.

o The existing trench which runs between the two ID fans.

o The Ash Bunker Substation building behind the ID fans, refer to drawing 0.61/96022 rev 4;

this drawing is only provided for information purposes.




The Contractor considers that this building restricts the turning radius of a vehicle

which is to enter the site via the access way situated between this building and the

adjacent ash conveyor.

o The Workshop building situated behind the ID fans, refer to drawing 0.61/96022 rev 4; this

drawing is only provided for information purposes.

o The close proximity of the ash conveyor next to the ID fans, refer to drawing 0.61/96022 rev

4; this drawing is provided for information purposes only.

o The close proximity of the inclined coal conveyor, refer to drawing 0.61/96022 rev 4; this

drawing is only provided for information purposes.

The Contractor is also aware that the inclined coal conveyor support structure poses

a height restriction on the access.

o The flue gas ducting from the ID fan outlet to the chimney.

The Contractor is also aware that this flue gas ducting poses a height restriction on

the access.

o There is a sump between the two ID fans

Due to the outage period, the Contractor carries out, as much as possible, work prior to the outage in

order to take advantage of the time available.




Figure 1: Conceptual site layout for purposes of communicating site constraints

Figure 1 is provided for information and illustrative purposes only; the intent of this figure is to communicate

Site constraints at the FFP outlet area. Figure 1 does not communicate the works itself.

Legend for Figure 1:

1. FFP outlet flue by the Contractor

2. DHP Blower House

3. Cable tunnel

4. Existing sump

5. Existing ID fan foundations

6. New ID fan foundations (concept not finalised)

7. Compressed air piping from the compressor house

8. New outlet flue support structure (concept not finalised)

9. Trench between existing ID fan foundations

10. Ductwork to chimney




5.2 Completion, testing, commissioning and correction of Defects

5.2.1 Work to be done by the Completion Date

On or before the Completion Date the Contractor has done everything required to Provide the Works except

for the work which may be done after the Completion Date. The Project Manager cannot certify Completion

until all the work has been done and is free of Defects.

The Contractor is available for the duration of three months after the return to service of the unit to assist with

the optimisation and performance tests of the retrofitted fabric filter plant. During this period the Project

Manager may instruct the Contractor to make good any part of the Plant the he deems not functioning as per

the design of the works. This activity does not constitute a compensation event.”

5.2.2 Use of the works before Completion has been certified

The Employer uses the works, without taking over the works, before Completion for the commissioning,

optimization and capability testing of the works and associated plants.

The Project Manager utilises Plant and Materials before Completion if there is an emergency which can

result in production losses of any of the power station units. The Project Manager notifies the Contractor of

the requirement for Plant and Materials to be utilised to prevent production losses. The time frame for the

use of Plant and Materials is agreed upon between the Project Manager and the Contractor.

5.2.3 Materials facilities and samples for tests and inspections

The following is supplied by the Contractor to the Employer for acceptance during testing, inspection or

commissioning.

5.2.3.1 FFP Tube Sheets

The Contractor submits, for acceptance by the Project Manager, two (2) sample tube sheets cut from plate

using the same laser programming procedure which is utilized, by the Contractor, on the works, before the

beginning the production run. These sample plates each contain one hole of the minimum diameter and one

hole of the maximum diameter. Refer to drawings listed in Appendix J. The Contractor supplies both the

plates to the Project Manager. The Employer will supply one of the plates to the FFP bag manufacturer.

The samples meet the tolerances as per drawings and Section 6.4.7. If the Project Manager finds that the

sample tube sheets to be unacceptable, the Contractor resubmits the sample tube sheets. The resubmittal

does not influence the Completion dates.

The Contractor submits the laser programming procedure used to cut the accepted sample tube sheets to

the Project Manager. This is the procedure used, by the Contractor, for the manufacturing of all the tube

sheets.

5.2.3.2 FFP Cages

The Contractor supplies sample cages to the Project Manager to check the fit with the fabric filter cages, by

others.




The Contractor supplies the filter bag cages as per the design conditions and requirements given in

Appendix E and section 6.4.4.

5.2.3.3 Pulse Valves

The Contractor provides sample pulse valves to the Project Manager for testing and acceptance before the

Contractor procures the pulse valves.

The Contractor submits two of the pulse valves for testing during/at tender. The Contractor as part of the

tender provides pricing on the pulse valve supplied.

5.2.4 Commissioning

Commissioning is defined as bringing into service all items of the works as specified, meeting the

requirements of the functional Works Information, as well as the control system and Plant and Materials

performance including all necessary testing and verification of the stated performance.

The works covered by the Works Information is installed and complete in all respects by the dates stated in

the Accepted Programme. The Contractor provides sufficient personnel for the satisfactory and timely

commissioning of the equipment.

Before Plant and Materials is placed in service, the Contractor certifies that it is in a suitable and safe

condition.

Prior to the time when cold commissioning commences, the Project Manager notifies the powers station

representative responsible for co-ordination of the commissioning of the generating unit such that the

commissioning of the works can be incorporated into the commissioning plan of the generating unit. .

The Contractor co-operates with the power station representative/s in the process of commissioning the

portions of then generating unit for which the Employer is responsible .

The Contractor develops a commissioning procedure that is submitted to the Project Manager for

acceptance.

Cold commissioning is defined as the period when individual items of the installation, electrical systems,

control and instrumentation systems are checked and tested.

The purpose of cold commissioning is that, following completion of no load checks; the plant is run without

load to certify that it is complete in all respects. The checks include but are not limited to:

• Final inspection of plant by commissioning engineers.

• Charge system with media.

• Ensure electrical power to motors is connected up.

• Direction checks of motors.

• Coupling alignment check.




• Eliminate any unacceptable vibrations.

• Thorough test of interlocks and protective systems. Replace all guards and covers removed to carry

out this work.

• Check calibration of all instrumentation such as level switches.

The purpose of hot commissioning is to prove the performance of the works to the Employer. The

Contractor's commissioning manager and his engineers, assisted by Employer’s engineers are responsible

for hot commissioning. The checks include but are not limited to:

• Coupling up to driven units.

• Setting driven units in motion.

• Check system integrity.

• Direction check of motors.

• Check the calibration and rectify where necessary all system instrumentation.

• Verification of sequence controls and interlocks.

• Check all process flows.

• Ensure pulse system (from compressors to blow pipes) shows leakage below 75kPa over a two hour

test period

• Complete all remedial work for acceptance by Project Manager.

• Train operating staff (at least 2 training sessions)

Contractor carry out a 72 hour proving period as required by Employer.

All commissioning activities will be done as per procedure, Commissioning and completion of refurbishment

project at Tutuka Power Station 240-114516712.

The Plant and Material covered by the Works Information is installed and complete in all respects by the

dates stated in the Accepted Programme. The Contractor provides sufficient personnel for the satisfactory

and timely commissioning of the Plant.

Before Plant is placed in service, the Contractor certifies that it is in a suitable and safe condition.

Prior to the time when cold commissioning commences, the Project Manager nominates a representative to

co-ordinate the commissioning of all plant forming an integral part of the plant being commissioned.




The Contractor co-operates fully with the Project Manager’s representative/s in the work of commissioning

the whole of the plant.

5.2.4.1 Cold Commissioning

During cold commissioning, individual items of the installation, electrical systems, control and instrumentation

systems are checked and tested.

All Electrical Plant and Material are to be subject to a subset of the routine tests, as part of cold

commissioning, as specified in the applicable standards (see Section 6.3). All Electrical Plant and Material

testing is to be conducted as per the documentation specified in the VDSS in Appendix B.

The Contractor performs functional checks. The functional tests form part of the cold commissioning of the

C&I system and are to include the checking of all measurement loops, interlocks, sequence controls and

analog controls.

The Contractor performs electrical drive tests, valve and damper tests. All dampers, drives, analogue and

binary valves are local and/or remote manual operated and checked for correct operation by the Contractor.

These tests are conducted in conjunction with the Supervisor and Others. Special care is given to safety

aspects, rotation direction, special function limits, torque settings, position indication and mechanical stops.

The Contractor is responsible for the setting of limits (stroke checking), torque settings and position

indication.

5.2.4.2 Hot Commissioning

The Contractor notifies the Project Manager that cold commissioning is complete and requests the

commencement of hot commissioning.

Hot commissioning begins after the acceptance (by the Supervisor) of cold commissioning tests

Results such as:

Quality assurance procedures and certificates.

Calibration certificates

Instrument Installation Quality Check Sheets, including labeling

NB :( Each instrument shall have its own installation quality check sheet for quality purposes, i.e. one check sheet shall not represent a group of instruments installed. This shall ensure that all instruments are checked accordingly)

Design reviews and factory inspections.

Loop checks sheets.

Cubicle, Instrument and HMI systems power supply connection and commissioning check sheets

The Contractor is responsible for the commissioning of the complete FFP control system in Unit 4-6 and FFP

pulse air control system (common plant) including the final control elements i.e. drives, switchgear

interposing relays, actuators, solenoid operated valves (SOV), existing actuators and their interposing, bus

interfaces and their protocols, relays as well as the HMI, station information system and LAN connection.




The Contractor interfaces with Others in Unit 1-3 while commissioning the complete plant system and FFP

control system, including the final control elements i.e. drives, switchgear interposing relays, actuators,

solenoid operated valves (SOV), existing actuators and their interposing, bus interfaces and their protocols,

relays as well as the HMI, station information system and LAN connection.

The commissioning activities are carried out in conjunction with the Supervisor.

The Contractor is responsible for the hot commissioning of all the Plant and Materials forming part of the

works to satisfy the requirements of the Works Information.

5.2.5 Start-up procedures required to put the works into operation

The Contractor provides a detailed list of special start-up requirements that need to be adhered to. This is

included in the detail design report.

The Contractor makes available a commissioning team consisting of subject matter experts to execute the

cold and hot commissioning of the constructed works.

The Contractor has available a competent team that can provide on-site advice and supervision and

execution of repairs or adjustments during cold and hot commissioning and additional 7 days after

completion of the commissioning.

5.2.6 Take over procedures

The Employer will only take over the works/parts of the works after all MDL and VDSS items are submitted

and spare parts list submitted.

This includes the information as requested in the Smart-Plant Data Take-On Standard (240-107305502),

refer to Section 3.7.

Take-over of the works will be executed once the relevant plant is fully commissioned and proven in

accordance with the requirements as set out in the Contractor’s procedures. All works take overs will be

done in accordance with the Eskom procedure “Commissioning and completion of refurbishment project at Tutuka Power Station 240-114516712”

5.2.7 Access given by the Employer for correction of Defects

The Contractor shall always notify the Supervisor for any defect correction when the plant is in operation.

5.2.8 Performance tests after Completion

The Contractor produces a detailed operational acceptance test procedure twenty working days before

commencement of the operational acceptance test, for acceptance by the Project Manager.

The C&I system is pre-tuned in order to prevent deviation limits of process parameters from exceeding the

maximum permissible values defined.

After satisfactory completion of installation and commissioning of the FFP and FFP pulse air equipment plant

C&I system, the Contractor demonstrates that the FFP and FFP pulse air C&I system successfully performs

the following:




Plant operated local and/or remotely manually.

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

Plant operated automatically (start-up, sequential control and shutdown) with all remote

supervisory/monitoring functions.

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

the plant.

All individual operating and control functions such as alarms, displays, report generation, historian

views, perform successfully.

Process server and Station plant information system functions are demonstrated, including process LAN and

client access operations according to the Works Information and all archiving and back-up functions.

The Contractor demonstrates that the individual units emit particulate emissions less than 30mg/Nm3 (on a

dry basis, normalized to 10% O2) at the stack.

The Contractor demonstrates that the compressors deliver the specified pressure to the pulsing system.

The Contractor demonstrates that the compressed air/pulsing system (from compressor to blowpipes)

maintains leakage less than 75kPa over a two hour period.

The Contractor notifies completion of operational acceptance tests.

The Contractor develops the optimization and capability acceptance tests procedure for acceptance by the

Project Manager. Optimisation and Capability acceptance tests proves that the C&I system is fully optimised

to meet the Works Information requirements as well as the safety of the plant system.

The Contractor provides all the resources required to complete optimisation and capability testing.

5.2.9 Training and technology transfer

The Contractor includes maintenance and operating manuals for all Plant and Material and equipment

supplied as part of the works. The Contractor submits the operating and maintenance manuals in both hard

and editable softs copies. All maintenance and operating manuals include the description of the Plant and

Material or equipment supplied and the AKZ numbers it applies to where applicable.

The Employer will provide training for the operation of the overall FFP.

The Contractor provides the training as described below.

5.2.9.1 C&I Training for Unit 1-6

This training is for maintenance and engineering personnel to prepare them for commissioning and

maintenance of the plant. The scope of training, as a minimum, includes field instrumentation set-up, use of

commissioning tools, signal loop drawings for trouble shooting, network configuration and system alarm

response procedure. This training is offered before cold commissioning begins. This training only focuses on




the new equipment, plant philosophies and protections provided by the FFP since the DCS system is familiar

to the C&I personnel.

The last part of training is for operating personnel to prepare them for commissioning and monitoring of the

plant after takeover. The scope of training, as a minimum, includes PFD’s, process design and operation, the

layout and information in the new mimics, the role of the control system in plant control (interlocks), the

limitations of the control system in plant control, alarms to be monitored and responded to. This training is

offered before cold commissioning begins.

Operating training need to be addressed to ensure required alarm descriptions and documentation as well as

isolation procedures are provided. The Contractor and the Employer revises the current light up procedures

which may require changes to plant settings as a result to the FFP retrofit project.

Training addresses the UPS and DC related plant to prepare maintenance and engineering personnel for

commissioning and maintenance.

5.2.9.2 C&I Training for Common Plant

This training is required on compressor’s PLC/Controller system configuration, network configuration and

logic functions for the engineering staff that will be involved with the commissioning. The training should also

focus on the new equipment, plant philosophies and protections provided for the common plants (e.g.

Compressor Plant). The last part of training includes the following as a minimum: PFD; process design and

operation; the layout and information in the new mimics; the role of the control system in plant control

(interlocks); the limitations of the control system in plant control, alarms to be monitored and responded to.

This training must be offered before the beginning of the commissioning phase of each Unit being retrofitted

to FFP’s.




6 Plant and Materials standards and workmanship

The specified Plant and Material is used, by the Contractor, in the Fabric Filter Plant installation at Tutuka

Power Station. The quantities for supply discussed are per Boiler Unit unless specified differently.

The Contractor performs all engineering and design in accordance with sound engineering principles and

prudent industry practice. The Contractor, and Contractor’s Subcontractors, performs the works in

compliance with legislation, rules and regulations, applicable national and international engineering,

environmental, construction, health and safety and other applicable standards and this Works Information.

The Contractor is completely responsible for engineering design. The Employer reviews and accepts, but

does not approve, the Contractor’s design. The Contractor is responsible to ensure compliance with the

Employer’s Works Information.

The Contractor includes all exceptions and/or clarifications to this works in Appendix A. The Contractor

includes the section deviated from as reference number and includes a detailed explanation of the deviation.

No deviation from this Works Information and its referenced documents is permissible without documented

approval from the Project Manager. In the event of conflicts or discrepancies between any of the

specifications, the Contractor notifies the Project Manager for resolution in writing.

The Contractor ensures that all units are in SI. Site conditions and utilities are listed in Appendix C.

All references to codes and standards as per the drawings referenced in Appendix J applies, their publications

are to the latest issue of each, together with the latest additions and/or amendments thereto, as of the

Contract Date, unless otherwise indicated. This does not relieve the Contractor from complying with all

applicable codes. Drawings referenced specifically in the following sections are for clarity on the specific

section of the works, the full set of Employer design drawings is included in Appendix J.

Where the referenced codes and standards contain recommendations in addition to requirements, the recommendations

are considered as requirements and are followed, by the Contractor, unless stated otherwise.

6.1 Investigation, survey and Site clearance

6.1.1 Site survey

The Contractor carries out a comprehensive site survey and verify coordinates, elevations and dimensions

with those shown on the drawings, a month prior to the commencement of any construction works. The

Contractor submits this site survey in the form of a report for acceptance by the Project Manager. This report

highlights any discrepancies, errors or omissions found in the survey. Station beacon coordinates are

provided in drawing 0.61/1101.

6.1.2 Geotechnical Investigation

The Contractor conducts a Geotechnical Investigation at the sites of the Site Construction Workshop, the

temporary FFP crane foundations, and each unit for each outage.




The Geotechnical Investigation conducted at each unit will at minimum include the following;

Drilling of boreholes to a maximum depth of 20m below ground level. The Contractor’s geotechnical

engineer ensures that the core runs produce adequate core recovery. The Contractor ensures that

all samples are adequately labelled and sealed prior to transport to the laboratory for testing.

On completion of drilling of each borehole the Contractor provides a log including at least the

following information:

1. Project designation, test pit number, type of equipment used

2. Name of logger in charge

3. Borehole depth and reason for stopping at that depth

4. Elevation of ground surface

5. Drilling log indicating the hole diameter, sampling (even if without success) and test results

6. Field classification of materials and stratification

7. Any other pertinent events, cavities encountered, heaving, etc.

8. RQD in rock strata

The following laboratory tests is carried out in accordance with the latest standard methods and

procedures as outlined by the appropriate authorities (B.S/ Euro Code equivalent, A.S.T.M,

A.A.S.H.T.O, I.S.R.M, S.A.B.S / S.A.N.S)

1. Point Load Tests

2. UCS Tests

3. Direct Shear Tests

No more than five of each of the above mentioned laboratory tests may be carried out per a borehole. The

Employer shall advise on the number of tests once the preliminary report has been reviewed

The works is carried out under the supervision of a Professional Geohydrologist or Geotechnical Engineer

and is registered with ECSA or SACNASP.

Immediately after the completion of the fieldworks and the laboratory testing the Contractor prepares and

submits a final site investigation report to the Project Manager for his acceptance. The final report is signed

by the responsible Geotechnical Engineer.

The final interpretive report includes at minimum the following:

Logs of boreholes describing layering, RQD, water inflows and all pertinent data regarding materials.

Calculation of RMR and Barton Q value

Description of the properties of pertinent soil and rock strata, discussion of bearing capacity,

settlements, swelling potential, settlement versus time.




The Contractor is to provide ultimate bearing capacities, allowable bearing capacity values and

foundation recommendations based on these bearing pressures

Detailed results, discussion and recommendations of all laboratory tests, classifications, saturation,

etc.

All field data and laboratory results are to be included in the appendices.

All raw data, calculations, tables, formulae, etc. used to develop recommendations to be included in

the report.

The final interpretive report is delivered as one electronic copy and one hard copy.

The Contractor may also carry out any additional investigations if deemed necessary to comply with the

scope. The Contractor submits his scope of the Geotechnical Investigation to the Project Manager for

acceptance. The Contractor may not proceed with the geotechnical investigation unless the Project Manager

has accepted the scope. The Employer reserves the right to share this information with Others.

6.1.3 Ground control survey

The Contractor conducts a ground control survey of underground utilities, services, trenches and tunnels that

might affect the positioning of structures, large equipment or construction equipment. This survey is

conducted for the area of the Site Construction Workshop location. The Contractor submits the perimeter of

the survey to the Project Manager for acceptance.

The position of underground services, underground utilities, trenches, vaults, exclusion zones and surface

penetrations are physically identified by the Contractor. The outcome of this survey is submitted to the

Project Manager in the form of a ground control survey report for acceptance.

The Contractor relocates underground services which interfere with the construction of the works only with

prior approval of the Project Manager.

6.2 Civil, structural and building works

The Contractor ensures that no air leakage, air ingress into the casing or flue gas leaking from the dirty to

clean gas side occurs. All steelwork exposed to elevated temperatures is suitably insulated and protected.

The Contractor carries out the civil and structural portion of the works in accordance to the Occupational

Health and Safety Act (85/1993): Construction Regulations, 2014 and the National Building Regulations.

No deviation from this Works Information is permissible without documented approval from the Project

Manager. The Contractor includes a list of exceptions and/or clarifications in his tender. This list of

exceptions includes the section as reference number, the requirement in question, and a detailed

explanation of the deviation.




The Contractor performs all shop detailing and fabrication in accordance with sound engineering principles

and prudent industry practice. The Contractor and his Subcontractors perform the work in accordance with

the specifications and standards included herein.

All references to standard/codes/publications are to the latest issue of each, together with the latest additions

and/or amendments thereto, as of the date of contract, unless otherwise indicated. This list is not all-

inclusive and does not relieve the Contractor from complying with all applicable codes.

6.2.1 Fabrication scope of the works

The Contractor is responsible for the supply of all materials, shop detailing, shop labour, consumable

materials, tools etc. for shop fabrication of all FFP components as a result of the works.

The Contractor is responsible to supply all materials shown on the Employer’s drawings, unless otherwise

stated on the drawings or in this Works Information.

The Contractor is responsible for detailed shop drawings. Shop drawings are submitted to the Project Manager for

his acceptance.

The Contractor furnishes and installs miscellaneous metalwork, including but not limited to, metalwork listed

in this clause and as shown on the Drawings or directed by the Project Manager:

supporting structural framework and cover plates, floor plates, gratings and hatch covers

pipe hangers and supports

ladders

metal doors

steel ladders

grid floors

6.2.2 Structural steel work

All steelwork is in accordance to the latest revision of the standards listed in Table 4.

Table 4: Steelwork codes and standards

Code Description

AWS D1.1 Structural welding code – steel

SANS 1921-3 Construction and management requirements for works contracts, Part 3: Structural

steelwork

SANS 50025 Hot rolled products of structural steels

SANS 1700 Fasteners

SANS 10162 The structural use of steel

SANS 2001-CS1 Construction works Part CS1 : Structural steelwork

BS EN 10210-2 Hot Finished Structural Hollow Sections of Non-Alloy and Fine Grain Structural




Code Description

Steels

SANS 455 Covered electrodes for manual arc welding of carbon steels

SANS 10094 The use of high-strength friction grip bolts

SANS 14399 High strength structural bolting

SANS 10160 Basis of structural design and actions for buildings and industrial structures

SANS 10120 Code of practice for use with standardised specifications for civil engineering

construction and contract documents

SANS 10021 The waterproofing of buildings (including damp-proofing and vapour barrier

installation)

SANS 10104 Handrailing and balustrading (safety aspects)

SANS 10177 Fire testing of materials, components and elements used in buildings

SANS 1200 Standardised specification for civil engineering construction

SANS 10064 The preparation of steel surfaces for coating

SANS 10400 The application of the National Building Regulations

SANS 121 Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and

test methods

SANS 10155 Accuracy in buildings

6.2.2.1Specification data associated with SANS 2001-CS1

The clause numbers listed in Table 5 refer to the clause numbers in SANS 2001-CS1. Table 5 must be read in conjunction with the SANS 2001-CS1.

Table 5: Specification data associated with SANS 2001-CS1

Clause Specification Data

4.1 Materials

4.1.1 The following clause is added:

“All structural steelwork is manufactured using grade S355JR steel. In the event of

any specified steel not being available, the Contractor notifies the Project Manager in

writing. The Project Manager replies in writing on alternative materials.”

4.1.5 All structural bolts and holding down bolts are of class 8.8 and nuts are of class 8,

unless otherwise specified on the Employer’s drawings.

4.2 Drawings

4.2.1.3 The clause is deleted and replaced with the following:

“All Drawings prepared by the Contractor is issued to the Project Manager in the





form of two paper prints and in electronic printable document format “PDF” and in

Native Format (dgn or dwg)”.

4.2.4.2 Attachments to facilitate erections do not remain as part of the permanent structure.

4.2.4.4 Hole sizes for holding-down bolts in excess of 36mm diameter are as follows:

Are not greater than 40mm.

4.2.4.7 Connections to allow movements are as shown on the Drawings.

4.2.4.8 The requirement for machining is as per the Employer’s design.

4.3 Workmanship (General)

4.3.6 The following clause is added:

“Flame cutting of holes is not permitted.”

4.4 Workmanship (Welding)

4.4.4.3 Tack welds are not to be incorporated into the final welds.

4.5 Workmanship (Bolting)

4.5.1.3 The natural protrusion beyond the nut is not less than 3mm, but not greater than

5mm.

4.5.1.4 Washers under nuts and bolt heads on flat surfaces are required

4.6 Workmanship (Erection)

4.6.2.1 The pressure or loading permitted on the hard standing is as per the Geotechnical

Investigation which was carried out by the Contractor and accepted by the Project

Manager.

5.3 Non-Destructive testing of welds (Welding)

5.3.4 Ultrasonic or radiographic examination is required for butt welds only.

5.3.5 Fillet welds are tested either with dye-penetration (DPI) or Magnetic Particle Inspection (MPI).

• 50% of the welds are tested

• The testing position is indicated by the Supervisor

• Butt welds are tested both with DPI or MPI and by Ultrasonic

• Drawings are to indicate the amount of required testing

Variations

1. Clause 4.1.2:

The chemical composition and mechanical properties of all steel incorporated into

structures is stated in the mill test certificates and submitted to the Project Manager





for acceptance.

2. Clause 4.2.4.2 and 4.4.4.5:

All attachments to facilitate erection are removed and holes are closed up after

erection.

3. Clause 4.4.4.3:

All tack welds are removed before welding, tack welds are not to be incorporated into

the final welds.

4. Add the following to clause 5.2:

The Contractor submits properly documented evidence of the qualification of the

welders to the Project Manager for acceptance. The Project Manager reserves the

right of testing the welder according to the welder’s qualification.

Additional clauses

1. The following clause is added to 4.2.4:

“Fabrication drawings are prepared by the Contractor. The drawings are issued to

the Project Manager for acceptance in the form of two paper prints and in “PDF”

electronic format and in Native Format (dgn or dwg). The Contractor does not

commence with fabrication until written acceptance from the Project Manager is

received.”

2. Add the following to clause 4.3.7:

Structures, composite units and bolted assemblies that comprise component parts

are not subjected to excessive stresses during the assembly, fabrication, or erection

process.


Any necessary straightening or forming is carried out by methods that neither

weaken nor deface the material.


The Contractor submits for acceptance full details of his proposed welding

procedures and the provisions of AWS apply to the acceptance thereof. Acceptance

of the welding procedures does not relieve the Contractor of his responsibility for

correct welding and for the minimising of distortion in the finished structure.

5. All main butt welds have complete penetration and wherever practicable are welded

from both sides. The backs of the first run are suitably gouged out.






Welds showing any planar defects such as cracks, lack of fusion or penetration and

excessive slag inclusions or porosity are cut out and rewelded. Under-cutting is not

permitted.

7. The Project Manager can instruct the Contractor to replace any welding equipment

which is unsuitable or unsatisfactory for the service in which it is being used.

8. Welders hold the relevant current welders qualification certificates.

9. All welders' tests are witnessed and/or accepted by the Project Manager before the

welder or operator is permitted to work. The decision of the Project Manager

regarding the acceptability of any test or existing qualification is final. Evidence of

previous qualification tests are accepted solely at the discretion of the Project

Manager.

10. Records showing the date and results of the qualification tests performed by each

welder and weld operator together with the identification number assigned to him is

at all times available for scrutiny by the Project Manager.

11. Each qualified welder and weld operator are assigned a unique identifying number.

This number is marked on the work in indelible crayon to establish the extent of

welds performed by the welder to whom it is assigned. Any welder or weld operator

whose work is subject to multiple rejections will be required to undergo a

re-qualification test on the appropriate weld procedure. At the discretion of the

Project Manager any welder or weld operator failing a re-qualification test may be

disqualified from any further welding on the works.

12. The Project Manager is informed of the necessity for repair or rectification work

before any attempt is made to carry out such repair. Approval is obtained from the

Project Manager prior to commencement of the work.

13. Weld repairs are made to the same procedure as for the original weld. All tests are

repeated after the repair has been completed and reports on radiographic and

ultrasonic tests are marked to indicate that the report refers to a repaired weld.

14. All metalwork for metal stairways, ladders, walkways and platforms are galvanised.

15. All plant, material and equipment are constructed of suitable material so that no

internal and external corrosion, erosion or distortion occurs when subjected to water

or corrosive substances, by virtue of its installation in the process. Plant service

environment is classified as atmospheric inland as defined by ISO 12944 C3.


Visual examination of all welds check that:





• there are no uneven leg lengths and there is no cracking or unacceptable undercutting or porosity, and

• full fusion is being achieved while welding is in progress.

17. Where required and prior to fabrication test certificates or cast analysis certificates,

or both, pertaining to the steel to be used are supplied to the Supervisor by the

Contractor.

18. The Contractor paints all applicable surfaces of the works.

19. All waterproofing is to be in accordance with SANS 10021.

20. All gutters and down pipes are provided to ensure free water flow away from the

works.

21. Grating is fixed with suitable grating clips and not welded such as Lindapter types GF

A.

22. Handling and lifting plant have sufficient capacity to ensure that steelwork is placed

in its final position without distortion or undue stressing of members.

23. Except where otherwise authorised in writing by the Supervisor, the Contractor

ensures that the work is carried out strictly in accordance with the Drawings supplied

to the Contractor by the Project manager or supplied by the Contractor and accepted

by the Project Manager.

24. Steel sections are provided as specified on the Drawings except that substitution by

larger sections is permitted with the Project Manager’s prior acceptance. Where the

Contractor wishes to make a substitution, he states his reasons and alternative

proposals in writing.

25. Clevises, bolts and nuts are stored in a dry enclosed area.

26. For the FFP, the construction is fully seal welded and pressure-tight. All corner

seams on flues are continuously welded to provide a gas and air tightness.

27. Splices:

All splices in platework for the FFP are full penetration welds as required to

maintain the full strength of the plate.

When a beam is required to be spliced, the Contractor obtains acceptance

from the Employer with regard to the location of the splice and the welding

procedure to be used.

Visual inspections of the root pass and final welds are required for splice





welds.

28. Arc strikes outside the area of permanent welds are to be avoided on any base

material. Cracks or other damage caused by arc strikes are ground to a smooth

contour.

29. All weld joints in areas to be covered by stiffeners are to be ground flush after

welding and prior to installation of stiffeners.

30. Tolerances for the FFP:

Tolerances for overall dimensions (length, width, height, etc.) are 3mm

unless otherwise specified by the drawing.

Assembled flue openings are square within 6mm for opening sizes up to an

including 245mm by 490mm. Opening sizes greater than 245mm by 490mm

are square within 585mm. Measurements are made diagonally.

Tolerances for door locations are +/- 9mm.

Tolerances for stiffener, channels, angles and bars are +/- 3mm non-

accumulative, unless noted of the drawing.

Tolerances for attachments such as supports, plates and pipes are located

within 3mm of the required drawing location.

The centre line of a bolt hole is aligned within 1.5mm of the drawing

dimension.

Bolt hole spacing is 3mm (non-accumulative) and 6mm (overall) of the

drawing dimension.

Bolt hole diameter is within 2mm of the drawing dimension.

Special tolerances are shown on the Employer’s drawings and take

precedence.

Unless otherwise specified by the drawing, tolerances for all overall

dimensions (length, width, height, etc.) are within 3m.

31. Module to module connections where flanges and rigid frames mate to form larger

components:

Fixed mating flanges or frames are parallel and square to all other structural

members in the mating models to within 50mm.

For horizontal module mating splices, a maximum gap of 4.5mm at any

location along the length of the mating member is acceptable.

For vertical module mating splices, a maximum gap of 6mm at any location

along the length of the mating member is acceptable.

Face flatness: The face of any module mating member, located along any

edge of the module, does not vary more than 3mm from the same plane.





The faces of all four sides of a module mating flange or frame are in the

same plane to within 4.5mm.

6.2.2.2 Specification data associated with SANS 1200 HA: Steelwork (structural) sundry items

Specification data pertaining to SANS 1200-HA is as listed in Table 6. The clause numbers listed in Table 6

refer to the clause numbers in SANS 1200-HA. Table 6 must be read in conjunction with the SANS 1200-

HA.

Table 6: Specification data associated with SANS 1200 HA

Clause Specification data

Variations

5.1.2 Add the following:

The shop details and other drawings are submitted to the Project Manager for acceptance at least 10 working days prior to fabrication.


Where no corrosion protection system is specified, open grid flooring is to be hot dipped galvanised.

7.1 Add the following:

Test certificates and cast analysis certificates is submitted by the Contractor to the Project Manager for acceptance.

6.2.2.3 Specification data associated with SANS 1200 HB: Cladding and sheeting

Specification data pertaining to SANS 1200-HB is as listed in Table 7. The clause numbers listed in Table 7

refer to the clause numbers in SANS 1200-HB. Table 7 must be read in conjunction with the SANS 1200-

HB.

Table 7: Specification data associated with SANS 1200 HB


Variations


Galvanized steel sheeting is to be coated with a minimum of 275g zinc per m2 and is to be free from white rust.

Additional Clauses





1 Where the use of nails and screws is required:

• Galvanised iron nails and screws are used for galvanized sheet iron and sheet zinc.

• Copper and copper alloy nails and screws are used for sheet copper and sheet lead.

• Aluminium alloy or stainless steel nails and screws are used for sheet aluminium.

2 Refer to the BRIL standard for insulation and cladding requirement of steel exposed

to elevated temperatures, Employer document number 360-1228.

6.2.2.4 Specification data associated with SANS 1200 HC: Corrosion protection of structural steel

Specification data pertaining to SANS 1200-HC is as listed in Table 8. The clause numbers listed in Table 8

refer to the clause numbers in SANS 1200-HC. Table 8 must be read in conjunction with the SANS 1200-

HC.

Table 8: Specification data associated with SANS 1200 HC


Variations


All burrs and sharp areas are removed by:

• Chamfering or

• Ground to a smooth radius of at least 1mm.


New structural steel is blast-cleaned according to SANS 10064 to achieve a cleanliness of SA 2.5 and coated with two Part Epoxy 250 micron. The colour matches the colour scheme of the existing Power Station structures and is to be accepted by Project Manager. The Contractor applies a heat resistance coating to steel at elevated temperatures.

Structural steel of existing structures to be incorporated in design are inspected and any surface rust are removed by steel brushing and painted to match the existing colour. The use of such steel is subject to acceptance by the Project Manager. Any structural steel member of the re-used structure that is excessively corroded are repaired or replaced.

Floor grating, stair treads, hand-railing and stanchions are hot-dipped galvanized (GSP 36-1126). Ductwork is coated with a zinc ethyl silicate primer and silicone acrylic topcoat.





3. Add the following to clause 5.4.3.1.b):

Dry abrasive blast cleaning:

• Blast cleaning media may not be recycled.


The coating system is hot-dip galvanising which is carried out in accordance with SANS 121:2011.

5. The works are adequately protected from physical damage and corrosion during

storage and erection.

6. All finished surfaces of ferrous metals, including screw threads that will be exposed

while awaiting installation are thoroughly cleaned and given a heavy uniform coating

of an approved petroleum soluble rust-preventive compound.

7. After erection, the works is to be inspected and any damage to painted areas must

be thoroughly cleaned, re-primed and painted.

8. All visible oil, grease, soil and other contaminants are removed.

9. Any loose paint, loose corrosion or any other type of loose particles are removed.

10. Prepared surfaces are to be cated before any visible or detreimentl corrosion occurs.

11. If corrosion forms after preparing the surface, then the surface is to be re-cleaned

prior to painting.

12. Sand or soft glass bead blasting are not acceptable for balsting the inside surface of

any pressure part components.

13. Grit of shot blasting is not used on surfaces that are to be non-destuctively examined

by ultrasonic method unless the surfaces are to be ground or mechined after blasting

and prior to examination.

14. Sand or soft glass bead blasting are acceptable for surface that are to be

nondestructively examined by ultrasonic method.

15. All machined surfaces are adequately masked off to avoid damage during blasting

operation.

16. All opening, which could trap the blasting media and are not readily accessible for





inspection or cleaning are plugged.

17. Before blasting, deposits of oil or grease are removed.

18. After blast cleaning, all deposits are removed.

19. Metal surfaces cleaned by blasintg are subject to inspection by the Supervisor prior

to painting.

20. All exposed steel (that are not galvanised) are painted with an inorganic zinc primer.

Additional to this, the view ports, vacuum breakers and access doors are also

painted. The paint specification is appropriate for steel at elevated temperatures, as

per the process information for the plant, where applicable. Minimum paint dry film

thickness is 2mm. Surfaces to be painted includes machined, mating, sliding and

bearing surfaces. No zinc-rich primer is applied to areas that are to be welded.

21. Paints and preservatives are to be stored and applied in a manner consistent with

their manufacturer’s recommendations, including method of application, mixing and

application restrictions. Paint is not applied to damp or frosted surfaces.

22. Lead containing paints are not used.

23. The Contractor is not to weld, cut, braze or grind any metal which has be painted

with a zinc coaring or any galvanised steel without first removing the coating.

24. Coatings containing metallic zonc are not to be applied to stainless steel.

6.2.3 Concrete works

All concrete work complies with SANS 2001-CC1-2012.

6.2.3.1 Specification data associated with SANS 2001-CC1

Specification data pertaining to SANS 2001-CC1 is as listed in Table 9. The clause listed in Table 9 refers to

the clause number in SANS 2001-CC1 and Table 9 must be read in conjunction with SANS 2001-CC1.

Table 9: Specification data associated with SANS 2001-CC1


Essential data

4.2 Materials

4.2.1.1 Cement will comply with the relevant requirements of CEM1-42.5, Ordinary Portland





Cement.

4.2.2 Water complies with the requirements of EN 1008.

4.2.3.1 The course aggregate nominal size is 19mm or 38mm.

4.2.3.4 Plums are not permitted.

4.2.3.5 The following tests are required:

a) Drying shrinkage on fine and coarse aggregates

b) Drying shrinkage of concrete

c) Flakiness index of the stone

d) Alkali-silica reaction

4.2.4.1 The use of admixtures is permitted, provided that the results of trial tests which

demonstrate their suitability and the following are submitted to the Project Manager

for his acceptance:

• The trade name of the admixture, its source and the manufacturers’

recommended method of use.

• Typical dosages and possible detrimental effects of under and over doses.

• Whether compounds are likely to cause corrosion of the reinforcement or

deterioration of the concrete.

• The average expected air content of freshly mixed concrete containing an

admixture that causes air to be entrained when the admixture is used at the

manufacturer’s recommended dose.

4.2.6 The grade of concrete is as follows:

• The minimum concrete grade for structural concrete is 35/19MPa or 35/38MPa.

• The minimum grade of blinding is 15/19MPa.

• The minimum grade of mass concrete is 15/19MPa or 15/38MPa.

o Mass concrete is defined as unreinforced concrete cast for fill in voids etc.

4.3 Formwork

4.3.1.5 Earth cuts may be used as forms for vertical surfaces.

4.3.1.8 The formed surfaces are as follows:

Formed Concrete

• A smooth finish is required for all formed concrete. To achieve this, finished

formwork is faced with steel, plywood complying with BS 1088 or equivalent

material in large sheets. The sheets are arranged in an accepted uniform

pattern. Wherever possible, joints between sheets are arranged to coincide with

architectural features or changes in direction of the surface. All joints between





panels are vertical and horizontal, unless otherwise directed. Suitable joints are

provided between sheets to maintain accurate alignment in the plane of the

sheets. Unfaced wrought boarding or standard steel panels are not permitted for

this finish unless authorised by the Project Manager or where specifically

detailed on the drawings.

4.3.1.8 The degree of accuracy required is II.

4.3.2.1.4 The design and drawings for the formwork and false work is submitted to the Project


4.4 Reinforcement

4.4.1.3 Bars may not be bent hot.

4.4.2.2 Welding of bars are not permitted.

4.4.3.1 The cover is as follows:

• The minimum cover to all steel to embedded foundations is 65mm.

• The minimum cover to all steel above ground is 50mm.

4.5 Holes, chases and fixing bolts

4.5.1 Fixtures to be embedded in the concrete are as per the Contractor’s design. This

design is accepted by the Project Manager.

4.7 Quality of concrete

4.7.3.2 Pumping of concrete is permitted.

4.7.4.1 Efflorescence on exposed concrete surfaces is not permitted

4.7.5.1 Concrete that has an air-dry density in the range 2000 kg/m3 to 2600 kg/m3 contains

entrained air that conforms to the limits given in table 6 in SANS 2001-CC1.

4.7.5.2 Concrete made to have an air-dry density that does not exceed 2000 kg/m3 contains

6% ±2% or 7% ±2% total air.

4.7.6.1 Mix designs and the mix test results are submitted to the Project Manager for

acceptance prior to the commencement of concrete work on Site.

4.7.12.1.1 Construction joints are required.

4.7.12.1.4 Proprietary bonding compounds between old and new concrete is permitted.

4.7.15.1 Exposed surfaces of concrete not finished against forms have the following surface

finishes:

• The surface, after the concrete has hardened sufficiently, is floated by hand or

machine sufficient only to produce a uniform surface free from screed marks.

5 Compliance with the requirements





5.1 Testing

5.1.1.7 The test results from a ready-mix production facility, as part of its quality control

system, is used.

5.1.1.8 The test for the percentage of alkali-aggregate is ASTM C289 – Potential reactivity of

aggregate (chemical method) or alternative method proposed by the Contractor and

accepted by the Project Manager.

5.1.2.3 The test results may be assessed statistically.

5.1.3.2 Samples of concrete are taken for each component of the structure for concrete

strength tests; however, samples are not taken on a frequency less than one sample

for each 50 m3 of concrete placed, one sample per day or one sample for each pour

of concrete placed, whichever is the more stringent.

5.2 Tolerances

5.2.1.1 The degree of accuracy is III for surfaces cast against earth cuts and II for other

concrete surfaces.

Variations

1. Add the following to clause 4.7.8.2:

The uninterrupted supply of the correct volume to Site is guaranteed if “ready-mixed”

concrete is used.


The space between pipes and ducts that are to be cast into reinforced concrete and

any adjacent reinforcement is not smaller than the larger of the following:

• 40mm, or,

• 5mm plus the maximum size of the coarse aggregate.

3. Add the following to clause 4.7.8.2:

The Project Manager may permit production of concrete at a central production

facility other than on the Site of construction and reserves the right to inspect for

acceptance of these central production facilities. The Contractor is responsible for

conducting all control testing.


Concrete may not be placed before the Supervisor has given permission in writing. A

minimum written notice period of 24 hours prior to pouring is required for each part of





the structure.

Additional Clauses

1 Cement and cement extenders is free flowing and free of lumps, and is supplied in

the manufacturer's sealed unbroken bags or in bulk. Material that has become

hardened or lumpy or fails to comply with the relevant standards in any way is

removed from the Site, without delay.

2 The materials used in the construction of falsework and formwork are suitable for the

purpose for which they are required and is of such a quality that will produce the

standard of work specified. The Contractor submits his proposal of the materials that

is used for the construction of the falsework and formwork to the Project Manage two

weeks prior to use for his acceptance.

3 The minimum blinding thickness is 75mm.

4. All reinforcement is hot rolled steel grade 450MPa.

5. Foundations and support slab are reinforced tri-dimensionally.

6. Prevention of plastic shrinkage cracks

The Contractor takes measures as necessary to prevent plastic shrinkage cracking

in the concrete. Particularly on dry windy days or hot sunny days, the Contractor

makes provision for fine spraying of the concrete surface with water as soon as it has

taken its initial set or covers the concrete with plastic sheeting. It may be necessary

to change the aggregates or the concrete mix proportions. In order to deal with

shrinkage cracking, it may be necessary to change the time at which, or the manner

in which, floating is carried out.

If plastic shrinkage cracking occurs, the cracks are be closed up by re-vibrating the

concrete while the concrete is still in a plastic state. Once the cracks have been

closed, the concrete is kept thoroughly wet, or covered with plastic sheeting for at

least a further three hours.

7. Curing of concrete

Details of the Contractor's proposals for curing concrete are submitted to the

Supervisor for agreement before the placing of concrete commences.






The average strength of the 3 cubes crushed is referred to as one test result. The

results are submitted to the Supervisor for his acceptance.


Provided the ambient air temperature does not fall below 10oC, no special

precautions need be taken to protect concrete from the effects of cold weather.

If the ambient air temperature is in the range 0oC to 10oC and freezing

conditions are confined to ground frosts during the night, the Contractor takes

the necessary precautions to ensure that concrete is placed and compacted at a

concrete temperature of not less than 5oC and that it is subsequently covered

and protected from cold winds and frosts to ensure that its temperature does not

fall below that shown in Table 10 for at least the period shown in the table. Such

precaution must be presented to the Supervisor for his approval.

When it is likely that the ambient air temperature will fall below 0oC, the

Contractor ceases with placing of concrete when the air temperature falls to

2oC and does not resume until it rises to 5oC,

Table 10: Concrete temperature during early life

Characteristic

Strength of

Concrete

Concrete to be maintained at not less than temperature shown

for a minimum period of :

2oC 5oC

10 MPa

20 MPa

30 MPa and above

10.0 days

4.5 days

3.0 days

8.0 days

3.5 days

2.5 days

Notes : i) The above periods are those estimated as

necessary for the concrete to gain a compressive

strength of 5 MPa.

ii) The periods required for other concrete strengths

and temperatures may be interpolated, but in no

case shall the maturing temperature fall below

2oC.

iii) The temperature referred to is the minimum at




Clause Specification dataany part of the concrete.

Concrete are not placed within formwork or in contact with reinforcement with a

temperature which is at or below 0oC and it is not placed against any surface bearing

frost or ice.


No placing of concrete takes place if the ambient temperature exceeds or is likely to

exceed 32°C or if there are hot drying winds during the casting period, without the

acceptance of the Supervisor.

Fresh concrete having a temperature exceeding 32oC are not placed in the works.

For pours of large volume where control of temperature rise or temperature

differential is critical, a lower maximum placing temperature, to be agreed with the

Supervisor, may be imposed. The Contractor takes all measures necessary to

ensure that the specified maximum placing temperature is not exceeded and that

loss of moisture during transporting and placing is reduced to the minimum. Such

measures are agreed with the Supervisor.

Areas in which concrete is to be placed are shielded from direct sunshine and rock or

concrete surfaces are thoroughly wetted if instructed by the Supervisor to reduce

absorption of water from the concrete placed on or against them.

After placing of concrete in any part of an area, the specified curing process

commences as soon as possible. If any interval occurs between completion of

placing and start of curing, the concrete are covered for this interval with polythene

sheet to prevent loss of moisture.

6.3 Electrical engineering works

The electrical engineering works comprise of implementing all the electrical systems required for the ESP to

FFP Retrofit project and adequately support the mechanical process design. The electrical engineering

works are to be executed in line with the requirements specified by the Employer’s design (See Section 3.1.2

and Section 3.1.3). The Contractor ensures that electrical systems are fully functional and are implemented

to achieve the required plant/process requirements.

This section also specifies the relevant regulations and standards to be applied for the detail design,

manufacturing, construction, and testing of the electrical equipment.




The Contractor provides all the necessary Plant and Material and equipment for the correct electrical

equipment operation, with high availability and maintainability, safe in use and correctly selected according to

environmental and site conditions.

6.3.1 Included in Electrical scope

The Contractor to manufacture/procure, transport, supply, install, test and commission the following:

Two new 11/3.3kV Cleaning Air Equipment Transformers.

Two new 3.3/0.4kV FFP Compressor Plant Transformers.

New LV switchgear to replace all the existing 380V Precipitator Boards A and B; i.e. 400V FFP

Boards A and B for Units 1 to 6 in the existing precipitator substations.

New 400V FFP Compressor House Boards A and B for the common cleaning air equipment

auxiliaries and other associated loads.

New Self Contained Battery Chargers (SCBC) to supply the DC auxiliary loads of the 400V FFP

Compressor House Boards A and B.

A UPS system to supply the I/O Panels and process signal transmitters for the new compressors in

the FFP and DHP Compressor House building. This also includes the batteries and battery

cabinets.

All new cabling and cable racking required for the 400V FFP Boards A and B loads. This includes all

protection and power (MV and LV) cabling.

All new cabling and cable racking required for the 3.3kV FFP Compressors, the 400V FFP

Compressor House Boards A and B loads and the four new Compressor Plant Transformers. This

includes all protection and power (MV and LV) cabling.

All new cabling and cable racking required for the new Battery Tripping Unit(s), and UPS system in

the compressor house building.

The power supply cables from the Unit UPS DB to the PA Sequencer and Bag Leak Detector DBs

for Units 1 to 6.

Lighting for all the Unit 1 to 6 FFP structures areas, as well as lighting inside each of the casings.

Small power for all the Unit 1 to 6 FFP structures areas.

Earthing and lightning protection system for the Unit 1 to 6 FFP structures and associated FFP plant

equipment.




Earthing of Compressor Plant equipment.

Construction Workshop Electrical Installation.

Also included is:

Decommissioning, dismantling and removal of existing 380V Precipitator Boards A and B and all

related cables for units 1 to 6.

Modification and testing of existing 380V Diesel Generator Boards A and B for units 1 to 6 to

accommodate the new lube oil pump motors for the ID Fan replacement project.

6.3.2 Voltage Levels

The rated voltage levels of the Plant will be as follows:

MV Switchgear : 11kV and 3.3kV

LV Switchgear : 400V

UPS System : 400/230V

DC System : 220V

All AC Plant and Material of the auxiliary system, except where otherwise specified, is capable of continuous

operation at a voltage level in the range 90% to 110% of the nominal voltage, and short-time operation at

75% of the nominal voltage during motor starting without deterioration.

The insulation levels of the Plant are in accordance with IEC 60071: Insulation Co-ordination.

6.3.3 Cabling and Racking

The Contractor procures, transports, supplies, installs, tests and commissions all cabling and cable racking

as described in the Employer’s design.

The Contractor provides all Cabling and Cable Racking documentation as required in the VDSS attached to

Appendix B.

The Contractor supplies, and installs all cable accessories such as terminations and jointing kits, cable

glands, lugs, bolts, washers and nuts for terminations, sleeves and other ancillary material for fitting the

cables into position. The Contractor provides all cable racking accessories as well.

For each cable type, the Contractor completes the Technical Schedule A and B that forms part of the Eskom

cabling standard 240-56227443: Requirements for Control and Power Cables for Power Stations Standard

(Rev 1).




The Contractor provides type test certificates for each cable type that forms part of the works.

6.3.3.1 Cable Specification

The Contractor provides MV cabling that comply with 240-56063792: 11kV and 22kV Impregnated Paper

and XLPE Insulated Cables Specification (Rev 1) as a minimum.

The Contractor provides LV cabling that comply with 240-56063805: LV Power and Control Cable with Rated

Voltage Standard (Rev 1) as a minimum.

The Contractor supplies and installs the cables and racking in accordance with 240-56227443:

Requirements for Control and Power Cables for Power Stations Standard (Rev 1).

The voltage rating of 11kV and 3.3kV XLPE cables is 6.35/11kV and 3.8/6.6kV respectively. The voltage

rating of LV power cables shall be 600/1000V.

6.3.3.2 Cable Schedules

The Contractor supplies and sets up work for medium and low voltage power plant in accordance with the

cable schedules developed. The Contractor notifies the Project Manager in the event of any change that is

required in the cables specified as detailed in the Employer’s Design, in order to satisfactorily complete the

works.

The Contractor routes all cables as per the cable routing specified, compiles the final cable schedules and

cable block diagrams, labels, and complete the applicable quality documentation and issues it to the Project


6.3.3.3 Cable Management System, Pull Cards and Drawings

The Cable Schedules is the control document for the cabling included in the works.

The Contractor installs the cables, test, terminate the electrical Plant and complete the cable pull cards. The

cable pull cards indicate the number of joints in the cables.

The cable pull cards contain the as-built status of the cables and the drum number from which the cable has

been pulled. The Contractor red-lines the cable block diagrams and submit such diagrams together with the

as-built cable schedules as per the cable pull cards to the Project Manager.

The Contractor provides and implements a cable drum management system. The Contractor compares this

to the Employer’s cable delivery to site management system and consolidates on a regular basis. All cable

deliveries to Site are logged on a cable drum delivery Schedule provided by the Contractor and accepted by

the Project Manager. The cable drum delivery Schedule is signed by both the Contractor and the Project

Manager. The Project Manager signs for acceptance only.

6.3.3.4 Marking of Cables




Cables is legibly marked in accordance with the requirements of SANS 1339 and SANS 1507 as applicable,

but the marking includes the specification number to which the cable has been manufactured, the conductor

size in mm2 and material e.g. Cu (copper). The PVC sheathed cables has a colour coded stripe in

accordance with SANS 1339 and bear the SABS mark.

The cables are sequentially marked at one meter intervals with the length indicated.

6.3.4 Low Voltage Switchgear

The requirements of the works as described in this section applies to the 400V FFP Boards A and B, for

Units 1 to 6, and the 400V FFP Compressor House Boards A and B.

The Contractor manufacture/procurement, transport, supply, install, test and commission the LV Switchgear

ASSEMBLIES in line with the requirements set by the Employer’s Design.

The Contractor ensures that all LV Switchgear complies with 240-56227516: LV Switchgear and Control

Gear Assemblies and Associated equipment for voltage up to and Including 1000V AC and 1500V DC

Standard (Revision 1).

The Contractor provides all documentation as required in the VDSS in Appendix B.

The Contractor makes use of 240-56227516 and Technical Schedules A and B (part of 240-56227516) for

writing the procurement specification or scope of work for the Contractor’s Subcontractors. This procurement

specification is subject to Project Manager’s acceptance.

The Contractor completes the Technical Schedules A and B which is part of the Employer’s standard 240-

56227516 during tender stage.

The Low Voltage Switchgear and Control gear assemblies provided for the project are of factory built Type

Tested Assembly (TTA) type that complies with the requirements of Technical Schedules (i.e. Schedules A

and B) and 240-56227516: LV Switchgear and Control Gear Assemblies and Associated Equipment for

Voltage up to and Including 1000V AC and 1500V DC Standard. The assemblies are of the free standing,

front-operated, and rear-access cabling type. Cable entry and distribution is from the bottom.

The Contractor shall ensure that the detail design and construction is in accordance with the 240-56227516

Employer’s standard. All LV board transformer incomer breakers are air circuit breakers (latching type

should be used) with separate protection equipment. All other LV board breakers are moulded case circuit

breakers / miniature circuit breakers or fuses/fused isolators for short circuit protection. When moulded case

circuit breakers are used, a condition monitoring function is installed for suitable replacement. The use of

moulded case circuit breakers or miniature circuit breakers depends on the system fault level and circuit load

(refer to 240-56357424 Rev 1).

The Contractor shall provide LV Switchboards that is Internal Arc Proof as per IEC 61641.




The Contractor shall ensure that all the protection devices comply with 240-56357424: MV and LV

Switchgear Protection Standard (Rev 1).

Modifications made to the 380V Diesel Generator Boards are to comply with 240-56227516: LV Switchgear

and Control Gear Assemblies and Associated equipment for voltage up to and Including 1000V AC and

1500V DC Standard (Revision 1).

The Contractor decommissions, dismantles and removes the existing 380V Precipitator Boards A and B and

all related cables for units 1 to 6.

6.3.5 Medium Voltage Motors

6.3.5.1 General

The Contractor provides MV Motors that comply with part A of Technical Schedule A and B for MV Motors, in

Appendix Y1 and Eskom standard 240-50237155 Rev 2 and SANS 60034 as a minimum. The Contractor

provides all documentation as required in the VDSS in Appendix B and the Employer’s standard 240-

50237155, for MV motors.

The Contractor provides a completed part B of MV Motor Technical Schedule A and B as per Appendix Y1,

at Tender and Detail Design Phases for the proposed and frozen MV Motors design respectively. Unless

otherwise indicated as “Only at Detail Design Phase” in Notes by User, all parts of Technical Schedule B will

be completed at Tender and Detail Design Phases. The excel format of Technical Schedule A and B is

available on request.

The Technical Schedule A and B will be required even in the case of the compressors being packaged unit.

MV motors for the compressors are rated at 3.3kV.

6.3.6 Low Voltage Motors

6.3.6.1 General

The Contractor provides LV Motors that comply with part A of Technical Schedule A and B, for LV motors, as

per Appendix Y2, 240-57617975 Rev 1 and SANS 60034 as a minimum.

The Contractor provides all LV Motor documentation as required in the VDSS in Appendix B and those

required by the Employer’s standard 240-57617975, for LV motors.

The Contractor makes use of 240-57617975 and Technical Schedules A and B (in Appendix Y2) for writing

the procurement specification or scope of work for the Contractor’s Subcontractors.

The Contractor only tenders service proven designs (all components). If a design has a component that has

not been proven for at least two years in service, the affected parts and the extent of their experience is

declared in the tender, for acceptance by the Employer.




The Contractor provides a completed Part B of Technical Schedule A and B as per Appendix Y2 of this

Works Information as per Appendix B.

6.3.7 Transformers

The medium power transformers (10MVA) comply with 240-68973110: Specification for Power Transformers

rated for 1.25MVA and above and with Highest Voltage of 2.2kV or above as a minimum.

The 630kVA transformers comply with 240-57648800: Specification for New Oil Filled Auxiliary Transformers

Rated 1 MVA and below and 33KV and below.

The Contractor provides all Transformer documentation as per the VDSS in Appendix B.

The Contractor makes use of 240-68973110, 240-57648800 and Technical Schedules A and B (in Appendix

Y3 and Y4) for writing the procurement specification or scope of work for the Contractor’s Subcontractors

that will be providing the transformers.

The Contractor completes Technical Schedule A and B in Appendix Y3, at tender stage for the 11/3.3kV

10MVA Dyn11 transformers.

The Contractor completes Technical Schedule A and B in Appendix Y4, at tender stage for the 3.3/0.4kV

630kVA Dyn11 transformers.

The transformer oil and all its testing requirements comply with 240-75661431: Mineral Insulating Oils

(Uninhibited and Inhibited) Part 1: Purchase, Management, Maintenance and Testing.

The Contractor supplies all the components required to move transformers in and out of their respective bays

(e.g. wheels and steel frames). The system is designed such that a transformer is removed from its bay in

the fastest time possible.

The MV/LV transformers (630kVA) neutral point on the low voltage winding is solidly grounded.

The MV/MV transformers (10MVA) neutral point is earthed via an earthing resistor. Each resistor is enclosed

in a naturally ventilated, protected, weather proof cubicle located outdoors alongside their respective

transformers and complying with IEC 60076-6.

The Contractor submits the general arrangement drawings of all transformers offered as per the VDSS

requirements.

6.3.8 Lighting and Small Power

The requirements specified in this section apply to the FFP area and the new Construction Workshop.




The Contractor provides all Lighting and Small Power Plant and Material required for the FFP area and the


The lighting and small power complies with 240-55714363 Coal Fired Power Stations Lighting and Small

Power Installation Standard (Revision 1) as a minimum. The lighting and small power system includes the

distribution boards, cables, conduits, wiring, luminary brackets, luminaries, and switch socket outlets.

Drawings comply with the following Employer’s standard drawings:

0.54/8579 Sheet 2-3: Standard Lighting Distribution Board Assemblies

0.54/8579 Sheet 4: Standard Lighting Distribution Board Layout Details

0.54/8579 Sheet 5: Standard Lighting Schematic Diagram and Layout Details

0.84/613: Standard Drawing Lighting Luminaire Schedule

0.00/10326: Eskom Standard Lighting, Telephones & Earth Mat Layout Symbols

In large size rooms, easy change of the bulbs and lamps has to be considered.

Where the rooms or corridors have more than one entrance/exit, multiple point switching is provided (one at

each access).

The Contractor provides distribution boards in accordance with 240-55714363 section 3.2.21. The

distribution boards utilised outdoors is IP65 rated and indoors IP55 rated. Locate small power panel boards

in a central location to reduce the extent of low voltage wiring for lighting and small power needs. The

distribution boards include approximately 20% spare capacity or a minimum of five spare circuits (whichever

is more) for future extension.

On completion of the installation, a certificate of compliance as stipulated in SANS 10142-1 must be issued

to the Project Manager in terms of the Occupational Health and Safety Act, (OHS Act 85 of 1993). The

qualified Contractor performs illumination measurements as recommended in SANS 10114. Illumination

measurement reports are produced and submitted to the Project Manager for acceptance. Measurements

are to be performed at night after the installation has been completed to design. This is the final measure of

the compliance to SANS 10114-1 illumination requirements.

The Contractor provides all Lighting and Small Power documentation as per the VDSS in Appendix B.

6.3.8.1 FFP Compartment Lighting

The Contractor installs lights on the inside of each FFP Compartment. The light is to be used to view the

tube sheet through the view port that is installed on the compartment, when the compartment is in use. The

switch for the light is on the outside of the compartment, such that the light/s can be switched on and off from

the outside of the compartment.




The Contractor submits a lighting study that includes the inside of the FFP compartments and clearly shows

that the tube sheet will be visible with the use of the installed light/s in the compartments.

The Contractor ensures that the light fittings can withstand the process conditions experienced on the inside

of the compartments. Refer to Appendix C.

6.3.9 Earthing and Lightning Protection

The requirements specified in this section apply to the FFP structure, the Compressor plant and the new


The earthing and lightning protection complies with 240-56356396: Earthing and Lightning Protection

Standard (Revision 1) as a minimum.

The Contractor ensures that all metal non-current carrying parts of the Plant are effectively connected to

earth. It is done by means of their mounting arrangement or by means of a special earthing conductor. The

earthing and lightning protection is in accordance with the Employer standard requirements 0.54/393, the

relevant SANS and IEEE 80.

The Contractor earths all electrical plant and material as required by the relevant standards. Earth bars have

been catered for in each room where new equipment is to be installed.

Conductors utilized for earthing are appropriate for the site’s soil conditions.

The Contractor is responsible for the earthing of the Plant and Material as required. The Contractor performs

earthing continuity tests as part of the quality control process. The tested earthing points must be marked

and recorded for reference purposes (plant earthing maintenance purposes). All installation plans must be

submitted to the Project Manager for testing witnessing purposes.

The Contractor clearly defines the philosophy and implementation (installation) plan for:

Lightning protection

Plant and Material earthing

System earthing (interfaces)

These shall be defined using drawings, calculation, software applied and all supporting documentation.

For equipment and personnel safety the Contractor provides earthing works in accordance with applicable

standards and submits to the Project Manager for acceptance of the design and all installations for

acceptance.

The Contractor provides all Earthing and Lightning Protection documentation as per the VDSS in

Appendix B.




6.3.10 Control Power Supplies

The uninterruptable power supplies, battery chargers, batteries and battery cabinets comply with the

following as a minimum:

240-53114248: Thyristor and Switch Mode Chargers, AC/DC to DC/AC Converters and

Inverter/Uninterruptible Power Supplies Standard (Rev 2)

240-56360086: Stationary Vented Nickel Cadmium Batteries Standard (Rev 2)

240-56176852: Essential Power Supplies for Power Stations Standard (Rev 1)

The Contractor makes use of Technical Schedules A and B to specify UPSs, battery chargers, batteries and

battery cabinets in accordance with the Employer’s standards mentioned within this section.

Each complete system is rated to supply the load of it UPS and DC board (for normal operation) and

simultaneously the load of the other UPS and DC board (in case of failure, for maintenance purpose or any

reason).

The Plant must be of a type tested design as per 240-53114248.

The Contractor makes use of nickel cadmium batteries with recombination units.

The batteries are installed in battery cabinets in accordance with schedule A&B of 240-56360086. The

battery cabinets come equipped with heaters.

The Contractor calculates the minimum ventilation requirements as per 240-53114234.

All alarms and indications are as per 240-53114248.

The Contractor completes Technical Schedule A & B in Appendix Y6, for the self-contained battery chargers

offered.

The Contractor completes Technical Schedule A & B in Appendix Y8, for the Stationary Vented Nickel

Cadmium Batteries offered.

The Contractor completes Technical Schedule A & B in Appendix Y7, for the UPSs offered.

The Contractor provides all Control Supplies documentation as per the VDSS in Appendix B.

6.3.11 Variable Speed Drives (VSDs)

Variable Speed Drives (VSDs) are required to supply the Ventilation Fan motors. These will be housed in the

400V FFP Boards A and B, for Units 1 to 6, as per the Employer’s Design documents. The requirements of

the VSD are conveyed in the technical schedule of Appendix Y5.

The VSDs comply with SANS 61800.




The Contractor provides all documentation as required in the VDSS in Appendix B and those required by the

Technical Schedule for VSDs in Appendix Y5.

VSD control interfaces will be finalised with the VSD supplier.

The Contractor provides all VSD documentation as per the VDSS in Appendix B.

6.4 Mechanical engineering works

The Contractor supplies the following parts of the works with reference to the rest of the Works Information.






Where the referenced codes and standards contain recommendations in addition to requirements, the recommendations

are considered as requirements and are followed, by the Contractor, unless stated otherwise.

6.4.1 Painting and Preservation

The Contractor ensures that all Plant and Material are protected by means of suitable paint systems, surface

coatings, linings, or finishes that are appropriate for the duty and environmental conditions typically found in

a power station's flue gas plant. As a minimum, all exposed non- stainless steel is coated with the applicable

spec for paintings and coatings. Refer to Section 6.2.2.4 Variation 2.

In no event do any items, Plant and Material, or equipment delivered hereunder contain chemicals,

substances, or materials in amounts or quantities greater than those specified in the Works Information. This

includes, but is not limited to; Asbestos, Lead, and DICHAN (dicyclohexylamine-nitrite or

dicyclohexylammonium-nitrite).

The Contractor provides touch-up finish paint with delivery at no additional cost to the Employer’s

recommendations.

The Contractor uses the following standards for paint,

SANS 1091

SANS 10140

SANS 10064

SANS 121

SANS 2808

Where other standards are called for on drawings the Contractor follows the instructions on the Employers

drawings.




Metal surfaces that will be in contact with hydraulic cement grouts are cleaned, by the Contractor, of all paint,

oil, grease, loose rust, and other foreign matter. The metal surface is sandblasted to bright metal and an

epoxy primer consisting of resin and converter is used over sandblasted surfaces to prevent corrosion. Final

surface preparation, by the Contractor, before application of grouting is in compliance with the Contractors

grout manufacturer’s recommendations.

6.4.2 Nameplates and Identification System

The Employer has assigned tag numbers to the P&ID’s as part of the Employers design, if the Contractor adds or

changes P&ID’s the Employer will assign tag numbers after the Contractor’s first submittal of P&ID’s to the Project

Manager.

Nameplates, labels, and their fixing screws is stainless steel, and are designed to last for the lifetime of the

plant. Refer to Section 2.2.9..

6.4.3 Welding Requirements

All welding procedures covering all forms of weld used on pressure vessels in the contract are in accordance

with Employer's standard 240-56241933, and are submitted to the Project Manager and the Appointed

Inspection Authority (AIA) for acceptance. Also refer to Section 6.2.2.

Electrodes are selected, by the Contractor, to be suitable for the welding application to be used.

The Contractor adheres to the following Employer standards where applicable;

240-56241933 - Control of Welding during Construction, Repairs and Maintenance Activities Standard

240-56241639 - Construction and Repair Welding of Primary Air, Induced and Forced Draught Fans Standard

240-56355225 - Welding of High Pressure Temperature Tube and Pipework Standard

240-56246601 - Qualification, Certification and Accreditation Requirements for Personnel and Entities Performing Welding Related Work on Eskom Plant Standard

240-77196678 - Heat Treatment of Welded Components Standard

6.4.3.1 Welders Qualifications

All welder qualifications are submitted to the Project Manager and the AIA for acceptance.

Welder qualifications are in accordance with Employer's standard 240-56241933.

The welders are qualified on Site under conditions simulating the conditions in the plant prior to any change

in welding procedures, materials and prior to employment.




6.4.4 Fabric filter cages

The design conditions for fabric filter cages supplied, by the Contractor, is summarized in the Technical

Design Information contained in Appendix E. Site data are as listed in Appendix C.


prudent industry practice. The Contractor, and Contractor’s Subcontractors, performs the work’s in

compliance with legislation, rules and regulations, applicable national and international engineering,

environmental, construction, health and safety and other applicable standards and this Works Information.

The Contractor ensures that fabric filter bag cages are free of sharp edges and burrs, which can damage the

fabric filter bag during installation or operation of the FFP.

The splice connection used to connect the fabric filter bag cage sections together are of the type shown in

Appendix E (Drawing B0222864). The Contractor uses a splice connection of the type shown in the drawing

B0222864 to connect fabric filter bag cage sections together.

The Contractor controls design and fit of the coupling connection to accomplish the following:

The fabric filter bag cages does not deform during assembly.

The fabric filter bag cages can be disassembled and re-assembled as needed over the life of the

filter bag cage without deformation of the filter bag cage or loss of joint integrity.

The assembled coupling connection is firm and does not work loose during the life of the fabric filter

bag cages.

The joint resists a minimum vertical load of 45 kg. A maximum load is established, by the

Contractor, at the time of the sample inspection.

No tools are permitted for joint disassembly.

Sheet metal used in the top of the cage and bottom of the cage is of the thickness shown in Appendix E.

The maximum spacing between the horizontal rings is 200 mm.

The Contractor furnishes and sends 4 completed fabric filter bag cages, to the Project Manager for fitting on

the FFP bags, supplied as free issue by the Employer. The Supervisor inspects and accepts the fabric filter

bag cages prior to the Contractor shipping the fabric filter bag cages to Site.

In the event that additional site services are required, the Contractor furnishes a qualified representative for

such service at the stipulated per diem rate in the Contractor’s proposal.

The Contractor ensures that workmanship and finish is equal to established practice in modern shops. All

materials worked have clean surfaces. Fabricated members are neat and accurate. Reasonable tolerances

are required for each component. See Appendix E for tolerances required. The Contractor ensures that no

item delivered or to be delivered hereunder contain an amount of lead in excess of 0.06% by weight in the

dried film.

6.4.5 Dampers

The Contractor supplies and installs the FFP Compartment Inlet, FFP Compartment Outlet, FFP Implosion

dampers and ventilation system dampers as per the requirements in the following sections.




The Contractor provides flexible connections to all the damper actuators.

6.4.5.1 Quality Control Requirements

All damper work - including engineering, design, material procurement, fabrication, and final shipment follows

the Contractor’s damper manufacturers written Quality Control Program or other specific manufacturer’s

requirements. Quality assurance procedures associated with this QCP is made available to the Project

Manager, upon request.

The Contractor advises the Project Manager at least 10 days prior to performing final inspection and testing

of damper equipment and two weeks before dampers are ready for shipment.

6.4.5.2 Poppet Dampers (FFP Compartment Inlet Dampers/Implosion Dampers)

The Contractor is completely responsible for manufacturing and fabrication engineering. The Employer

accepts, but will not approve, the Contractor’s work to check compliance. It is the Contractors responsibility

to ensure compliance with the Employer’s Works Information.

All flue gas dampers have a padlock system (supplied with pad lock and 2 keys). The Contractor includes

details of construction with the tender. The pad lock provisions prevent movement from the closed position.

Certified Material test reports are furnished for each alloy heat, by the Contractor. All Material components of

the damper must meet the applicable ASTM Specification for dimensional tolerances and SSPC-SP3 for

surface condition see Appendix H. The Plant and Material as listed in Appendix H is not necessarily a

complete list of Plant and Material to be supplied by the Contractor. The Contractor is responsible for

supplying all Plant and Material required for a complete operating system.

Gas velocities through the FFP Outlet Dampers are 12.7 m/s nominal (operating temperature and design

flow).

Electrodes for welding are selected to be suitable for the welding application to be used.

6.4.5.2.1 Painting and

Preservation

Exposed areas at the inlet dampers (same as other dampers) such as operator components and related

frame is finish painted. External surfaces receive standard rust inhibitive primer and suitable finish in the

shop. Dry film thickness for primer and finish coats is as recommended by the paint manufacturer.

Damper blade and shaft receives one coat of self-curing dual-component ethyl silicate- based inorganic zinc.

Dry film thickness for Inorganic zinc is 3-5 mills (75 – 125 microns). Refer to Section .

6.4.5.2.2 Poppet

Dampers Controls

The Contractor supplies a detailed description outlining the control philosophy. The write-up includes, but is

not limited to, start-up, shutdown, normal operation and special operating procedures. It also includes all




permissives and interlocks. All instrumentation provided is of NEMA 4X enclosure type. An isolation valve

(root valve) is supplied, by the Contractor, for each instrument.

6.4.5.2.3 Electrical

Unless indicated otherwise, the Contractor provides four (4) internal actuator limit switches and two (2) frame

mounted limit switches for each pneumatically actuated damper (independent of actuator). Refer to the

damper design data sheets in Appendix H for limit switch requirements for the pneumatically actuated

dampers. The damper drive, limit switches and other electrical components are mounted on the damper by

the damper manufacturer and permanently wired in conduit. The Contractor ensures that wiring conduit

placement is such to avoid all interferences with the drive linkage.

Power available for solenoid valves is 220v, 50 Hz. The Contractor supplies space heaters for motor

operator electrical compartment. Actuators supplied by the Contractor have a safety factor of no less than

200%. All pneumatic drives include dual coil solenoids valves to allow for fail in place. Pneumatic drives are

double acting, sized to operate at 483 kPa min to 827 kPa, max compressed air supply.

6.4.5.3 Louver Dampers (FFP Compartment Inlet Dampers)

The design conditions for the Plant and Material to be supplied, by the Contractor, are summarized in the

Technical Design Information contained in Appendix G.

The Contractor is completely responsible for engineering design. The Employer may review, but will not

approve, the Contractor’s work to check compliance. It is the Contractor’s responsibility to ensure compliance

with the Employer’s specifications.

The compartment inlet dampers open to the direction as shown on the Employers drawings.

All flue gas dampers have a padlock system (supplied with pad lock and 2 keys). The Contractor includes

details of construction at tender. The pad lock provision prevents movement from the closed position. Parallel

louver damper blades overlap a minimum of 10 mm when closed to provide sealing even in the event of total

seal failure.

The Contractor is responsible for supplying all Plant and Material required for a complete operating system.

This includes all valves and instrumentation required for the safe and dependable operation of the system.

If the Contractor thinks that additional Plant and Material is necessary for the system to operate, the Contractor

quotes this additional Plant and Materials and supplies an explanation of why it is necessary to the Project

Manager.

Certified material test reports are furnished, by the Contractor, for each alloy heat.

The Contractor ensures that all material components of the damper meet the applicable ASTM Specification

for dimensional tolerances and SSPC-SP3 for surface condition.

For louver damper seal design, blade/shaft design specifications see Appendix G.




The Contractor ensures that electrodes selected for welding are suitable for the welding application to be

used.

6.4.5.3.1 Drive

System

For large damper sizes, temperature differentials between the hot damper frame and external linkage could

cause the blades to open slightly. Because this is unacceptable for tight shut off applications on large

dampers, the Contractor provides a design that does not permit unacceptable leakage while in the closed

position during operating conditions. The Contractors design includes an insulation box which encloses the

entire external linkage assembly or a thermally compensating linkage (if accepted by the Project Manager.)

The end of each shaft includes a visible, permanent external indication of each blade position.

Drives which are integrally mounted as part of the damper assembly may be removed during the construction

stage to protect the drive assembly from potential damage. Therefore, drive assembly must be properly

identified (or match marked), by the Contractor to ensure the same drive goes back onto the same damper

assembly from which it was removed.

6.4.5.3.2 Bearings

and Packing Glands

Internal bearings (and internal linkage) may be used provided that they are self-cleaning, the Contractor

obtains acceptance from the Project Manager before use of internal bearings. (Note that penetration of the

frame with the associated sealing maintenance for example lubrication is not allowed.)

When external bearings are used, they are to be the self-aligning and self-lubricating with a mounting block

and a packing box. When required by the Contractor’s supplied dampers, provisions for seal air to the

packing box is clearly indicated.

Bearings are selected on the basis of both the ambient conditions at the location where the damper is

installed and on the basis of temperature transmission from the damper shaft to the bearings. To ensure that

damper bearings are truly maintenance free, only sleeve bearings are acceptable. BALL BEARINGS MAY

NOT BE USED FOR ANY DAMPER APPLICATION. A stainless steel damper shaft (or stub shaft) is

typically required with a sleeve bearing.

A chrome plated carbon steel shaft or a carbon steel shaft with a stainless steel collar (sleeve or bushing)

may be used in the area of the bearing. The Contractor’s design takes into account any differential growth

between the damper shaft and the sleeve material.

Bearings are positioned with sufficient distance from packing glands to avoid flue gas contamination if failure

of packing occurs.




6.4.5.3.3 Louver

Dampers Controls

The Contractor supplies a detailed description outlining the control philosophy. The write-up includes, but is

not limited to, start-up, shutdown, normal operation and special operating procedures. It also includes all

permissives and interlocks. All instrumentation provided is of NEMA 4X enclosure type. An isolation valve

(root valve) is supplied, by the Contractor, for each instrument.

6.4.5.3.4 Electrical

Unless indicated otherwise, the Contractor provides four (4) internal actuator limit switches and two (2) frame

mounted limit switches for each pneumatically actuated louver dampers (independent of actuator). Refer to

the damper design data sheets in Appendix G for limit switch requirements for the pneumatically actuated

louver dampers. The damper drive, limit switches and other electrical components are mounted on the

damper by the damper manufacturer and permanently wired in conduit. The Contractor ensures that wiring

conduit placement is such to avoid all interferences with the drive linkage.

Power available for solenoid valves is 220v, 50 Hz. The Contractor supplies space heaters for motor

operator electrical compartment. Actuators supplied by the Contractor have a safety factor of no less than

200%. All pneumatic drives include dual coil solenoids valves to allow for fail in place. Pneumatic drives are

double acting, sized to operate at 483 kPa min to 827 kPa max compressed air supply.

6.4.5.3.5 Painting and

Preservation

Exposed areas at the inlet dampers (same as other dampers) such as operator components and related

frame is finish painted. External surfaces receive standard rust inhibitive primer and suitable finish in the

shop. Dry film thickness for primer and finish coats is as recommended by the paint manufacturer.

Damper blade and shaft receives one coat of self-curing dual-component ethyl silicate- based inorganic zinc.

Dry film thickness for Inorganic zinc is 3-5 mills (75 – 125 microns). Refer to Section .

6.4.6 Valves

The design conditions for the valves to be supplied, by the Contractor, are summarized in the Valve Lists

contained in Appendix I and Appendix V.

The Contractor is completely responsible for engineering design. The Employer reviews and accepts but will

not approve, the Contractor’s work to check compliance. It is the Contractor’s responsibility to ensure

compliance with the Employers specifications.

The valves supplied by the Contractor are as shown on the valve lists in Appendix I and Appendix V.

The Contractor is responsible for final materials selection based on the information supplied by the

Employer. The materials given in the valve lists are recommendations only.

The design pressure indicated on the valve list references the valve pressure class that the Contractor

supplies.




Flanged end connections for valves <100mm has a bolt hole pattern compatible with ANSI B16.5 Class 150

flanges. Flanged end connections for valves >=100mm has a bolt hole pattern compatible with AWWA C207

Class D flanges.

All valves a r e dual sealed, resistant seated and capable of sealing against any pressure up to the

specified shut-off pressure in either direction. Further the valves are capable of operating (opening and

closing) at any pressure up to the specified shut-off pressure applied to only one side of the valve and

sustain no damage.

All valves has the following stamped or cast on the body: manufacturer's name, the nominal valve size,

directional flow arrow, and the primary service pressure rating for which each valve is designed.

The noise level produced by the valve does not exceed 85 dBA at a distance of one (1) meter from the

valve.

On/Off valves a re tight shut-off. Throttling (modulating control) type valves leakage is Class IV

minimum. All valves are hydro tested to 1.5 times the rated pressure of the valve.

The locations of the valves are as per the drawings supplied to the Contractor. If the locations need to be

altered to meet the requirements of the Works Information the Contractor indicates the locations on drawings

and submits for acceptance to the Project Manager before continuing with installation. The Contractor installs

the valves in areas/locations where maintenance can be performed with reasonable ease and safe access

from platforms.

The Contractor supplies drawings of each type of installed valve to the Employer. The Contractor supplies as

built information and drawings to the Employer prior to handover.

All automated valves are given a shop operational test to verify proper operation of the valve, the actuator,


The Contractor’s quality program provides for the collection and retention of inspection data. The following

documents are submitted to the Employer.

Prior to Fabrication

1. Welding Procedures to be utilized

2. A Quality Plan as generally described in the Works.

3. General Arrangement drawing showing as a minimum, heights, widths, lengths, location of

connections, type of construction, weld joint details, and dimensional tolerances.

After Completion of Fabrication

1. An "as-fabricated" drawing if the equipment is different from that of the originally approved drawing.

2. Certificates of Compliance for fasteners.

4. Results of any performance testing.

5. A listing of any approved deviations with supporting documentation.




6.4.6.1 Valve Type Specifics

6.4.6.1.1 Ball valve

Ball valves a re of the three piece design unless flanged end connections are provided. Flanged ball valves are of the two piece design. Ball valves are full port.

6.4.6.1.2 Butterfly

Rubber molded body linings extend over the valve body face. Butterfly valves are installed such that the

shafts are horizontal.

6.4.6.1.3 Pressure

Relief

At specified inlet and outlet pressures, the Contractor provides max flow rate and full open Cv with

tender. (for FFP air supply header applications, design conditions for pressure relief valve to be revised

once pressure regulating valve failure flowrate is known.)

The Contractor sets the pressure relief valve at a pressure which will protect the pulse valves from seeing

too high of a pressure. The pulse valves used for design by the Employer are typically rated for a max

pressure of 690 kPa. In the event that the pressure regulating valve upstream fails and the pressure of the

pulse air increases to 690 kPa the pressure relief valve opens and blow off the excess pressure.

The Contractor uses the maximum flow through the fully open pressure regulating valve (from the valve

supplier) and sizes the pressure relief valve.

The operating pressure listed in the valve list, Appendix I, 360-190, was put at 552 kPa for the pressure relief

valve since they will normally only see the regulated pressure of 552 kPa. The design pressure was selected

as 690 kPa, since the pressure will be relieved at this pressure in the event that the regulating valve fails.

The Contractor completes the data pages in Appendix L and supplies the data pages to the Employer for

acceptance of the valves before purchase.

6.4.6.1.4 Pressure

Regulating

The Contractor supplies externally sensed regulating valves with tight shut off resilient seals. The resilient

seat is required to prevent pressure build up downstream of the valve during periods of no flow through

demand. The Contractor supplies flanged pressure regulating valves with body sizes greater than 50 mm

and threaded for body sizes 5 mm and smaller. For FFP Air Supply Header applications, the Contractor

supplies flowrate at full-open failure position based on the specified inlet design pressure of 690-863 kPaG

and an outlet design pressure of 414-552 kPaG (pressure relief valve set-point pressure located

downstream of pressure regulating valve).

The Contractor completes the data pages in Appendix L and supplies the data pages to the Employer for

acceptance of the valves before purchase.




6.4.6.2 Operator (Actuator) Design

The Contractor supplies all manual, pneumatic, or electric operators as called for in Appendix I. (Valve

List).

For slurry applications, valve operators (whether manual, pneumatic, or electric) are sized to ensure

operation when scale become deposited within the valve.

The Contractor prior to shipment strokes all valve operators with adjustable mechanical stops and set the

mechanical stops to ensure proper operation of the valve.

Manual Op e rators (H)

Manual operated valves include an operator that limits the force required for actuation against the shut-off

pressure to 61 Nm. Gear operators are provided on all valves larger than 150mm.

Pneumatic On/Off Act u ators (POF)

The Contractor does not substituted electric operators where pneumatic operators are specified. The

pneumatic actuator does not suffer damage if driven against a mechanical stop. Valves which require a 90

degree pneumatic operator is provided with either a dual rack and pinion or a pinned scotch yoke operator.

Actuators are sized to operate at a minimum of 550 kPa. The Contractor is responsible for taking into

account pressure losses due to solenoids, tubing, etc. when sizing the actuator.

The Contractor ensures that use of air regulators and filters are minimized. If an air regulator or filter is

required the Contractor supplies a Fisher CFR67 as part of the valve assembly. (If the instrument air piping

is carbon steel then it is required that and air filter regulator be provided. If the piping is

stainless/copper/galvanized then an air filter regulator is not required unless the Works Information

requires one or the Contractor requires one to protect the cylinder.)

The minimum instrument air pressure available to the Contractor is 450 kPa(g) and the maximum is 690

kPa(g).

Failure Positions

The valve failure position is defined in terms of loss of air (LOA) and loss of signal (LOS).

Pneumatic On/Off valves designated as "FIP" during LOA and “FIP" during LOS fail-in-place

upon loss of air or solenoid power. This is accomplished by means of a double acting cylinder

with a dual coil solenoid.

Pneumatic On/Off valves designated as "FIP" during LOA and "FO" during LOS fail in place

upon loss of air and fail open upon loss of solenoid power. This is accomplished by means of a

double acting cylinder with a 4 way single coil solenoid.

Pneumatic On/Off valves designated as "FIP" during LOA and "FC" during LOS fail in place upon

loss of air and fail closed upon loss of solenoid power. This is accomplished by means of a double

acting cylinder with a 4 way single coil solenoid.




Pneumatic On/Off valves designated as "FO” during LOA and "FO" during LOS fail open upon loss

of air or solenoid power. This is accomplished by means of a spring return cylinder with a 3 way

single coil solenoid.

Pneumatic On/Off valves designated as "FC” during LOA and "FC" during LOS fail closed upon

loss of air or solenoid power. This is accomplished by means of a spring return cylinder with a 3

way single coil solenoid.

Limit Switches

All pneumatic on/off valves shall be supplied with two (2) limit switches (1 open/1 close).

Limit switches shall be SPDT design.

Limit switches are of NEMA 4X design, or they are located in a NEMA 4X enclosure.

The power source for the limit switches are defined by the Employer. The mechanical and electrical

sides of the switches are separated by a barrier.

Limit switches use dry contacts interrogated with 24/48 Vdc voltage from the DCS.

Switches can be either mechanical or proximity type. Proximity type switches shall utilize a

magnetic target.

The Contractor is responsible for selecting the make of limit switch. The selected switch must

comply with all of the above requirements.

Solenoids

For actuators designated "FIP" during LOA a n d “FIP” during LOS, a 4- way dual coil standard

temperature rated solenoid shall be provided.

For actuators designated “FIP” during LOA and "FO" or "FC" during LOS, a 4-way single coil high

temperature rated solenoid shall be provided

For actuators designated "FO” or “FC” during LOA and “FO” or “FC” during LOS, a 3-way

single coil high temperature rated solenoid shall be provided.

All solenoid valves shall be of NEMA 4X design, or they shall be located in a NEMA 4X enclosure.

The power source for the solenoids will be defined by the customer.

All solenoids shall be provided with a manual operator. This override shall be of the momentary

type.

Spool type solenoids are not acceptable.

ASCO solenoids are provided.

The Contractor ensures that instrument air tubing and fittings are as per requirements in 240-56355754,

Field Instrument Installation Standard.

The actuators are provided with manual speed controls to offer some adjustability in open/close times.

Quarter turn valves are supplied, by the Contractor, with a snubber on the solenoid exhaust port. Linear

valves are supplied with in-line flow control valves. The speed control devices are of all brass construction.

Each valve is shipped, by the Contractor, with its operator and all its accessories mounted, connected,

and wired to a common junction box.




6.4.7 FFP Tube sheet

The Contractor develops shop details and fabricate based on the information presented in this Works

Information and on the DEA drawings as listed in Appendix J.

The Contractor performs inspections as required to assure dimensional compliance of the fabricated parts of

the tube sheet with the DEA drawings.

The Contractor performs NDE (Non-destructive examination) of shop welds per this Works Information and

the DEA drawings. Refer to Section 6.2.2. The Contractor performs all inspections as required by the

Contractor’s submitted Quality assurance program. The Contractor includes all handling and lifting

Equipment necessary to safely load the tube sheet ship assemblies, onto transport carrier(s) without damage

to the assemblies.

The Contractor includes all handling and shipping braces and tie- downs required to safely transport the tube

sheet ship assemblies to the Site. This includes the design of all necessary temporary braces and ties

necessary when stacking tube sheets for shipping.

The Contractor procures and controls materials in accordance with the Contractor’s Quality Assurance

program. The Contractor ensures that materials are as listed on the DEA drawing lead sheet.

To achieve the specified as erected component tolerances, the Contractor carefully dimensions component

parts, specifying part tolerances as required. Fabrication and erection effects such as weld shrinkage are

considered, by the Contractor, when detailing component parts.

The Contractor’s drafting practices used conforms to AISC and AWS requirements. All work is neat and

legible, and equal to the best in modern drafting practice.

The Contractor indicates the location of shop splices on the detail drawings. Shop splices are full penetration

welds. The Contractor holds the use of shop splices to a minimum.

Deviation from the DEA drawings or this Works Information requires written acceptance from the Project

Manager. This includes, but is not limited to, requests for substitution of materials, weld details, structural

shapes, and plate sizes. Any ambiguities, errors or inconsistencies noted by the Contractor are reported in

writing to the Project Manager for resolution, prior to material procurement and fabrication.

The Contractor identifies all welds by the recommended AWS A2.4 symbols. All weld details are in

accordance with AWS D1.1 unless otherwise accepted by the Project Manager in writing.

The Contractor performs all work in strict accordance with the drawings and this Works Information. The

workmanship and finish of everything is equal to the best practice in modern fabrication and manufacturing.

Fabricated components are made up of the largest practical widths (or lengths) of plate or structural

members available.




The Contractor assures the proper fit of the fabricated components. All costs associated with any field

modification to the fabricated components necessary to achieve the as-erected tolerance is assumed by the

Contractor.

The Contractor dimensionally verifies that the completed components are within the tolerances specified on

the design drawings as listed in Appendix J. The Contractor records all measurement. Any correction

needed to bring the fabricated component into compliance is done prior to shipment at the Contractor’s

expense without schedule relief.

Under no circumstances are shop splice welds closer than 25 mm from any tube sheet hole. This

requirement is included in the Contractors QCP.

Blanking plates are used to cover and seal tube sheet holes at locations where bag damage reoccurs due to

special circumstances such as local clearance damage between the stiffeners. See referenced drawings in

Appendix J for details. The Contractor supplies 200 blanking plates as part of the works.

The Contractor manufactures and supplies 3 (three) Rock-No-Rock gauges as part of the works as per the

drawings provided by the Employer. Tube sheet flatness is verified by the Contractor, using the Rock-No-

Rock gauge. The Rock-No-Rock gauges are handed over to the Project Manager with the completion of

commissioning of each FFP Unit. The Contractor supplies one Rock-No-Rock gauge as part of the Enquiry

documents.

The Contractor controls the holes in the tube sheet to the diameter as specified on the drawings. The

tolerance is critical to fit up of the bag. The hole diameter is verified by caliper measurement, by the

Contractor. The acceptance criteria for hole diameter is that no 2 points along the diameter is outside the

tolerances specified on the drawings. The Contractor provides the results of the measurements to the

Supervisor.

The holes must be held to a roundness tolerance as specified in the drawings. (Maximum diameter minus

minimum diameter). The hole roundness is verified by caliper measurement, by the Contractor. The

Contractor provides the results of the measurements to the Supervisor.

The Contractor ensures that holes do not taper more than 0.127 mm from top of hole to bottom of hole. This

is verified by caliper measurement, by the Contractor. The Contractor provides the results of the

measurements to the Supervisor.

Laser cutting is the preferred method of fabrication. Due to limitations of fabricating equipment it is

anticipated that, all tube sheets will end up being shop spliced to form the assembly. Flatness of the tube

sheet is critical. The Contractor follows weld procedures which produce the flatness required. The

Contractor performs testing prior to start of fabrication to insure the tube sheet flatness is achieved. The

Contractor provides results of the testing to the Supervisor.

The Contractor ensures programming of the laser cutting is critical to achieving the desired hole

smoothness. The laser start of cut is not permitted within 6 mm of the tube sheet hole edge.




The Contractor ensures that shop splices of the tube sheet are no closer than 1475 mm apart. The plate

edges of shop and field splices are laser cut or sheared to ensure straightness and to prevent excessive

warpage.

The Contractor ensures that handling in the shop is by means of the lifting frame to prevent damage of the

tube sheet assembly during handling and loading, particularly flatness and hole damage. This same lifting

frame is used by the Contractor for unloading and for erection. See DEA drawings. The lifting rig is

composed of spreader assembly with multiple lift chain pickups. The lift chain pickups are positioned to

provide support for each vertical support member of the tube sheet. The spreader width is set to provide

support at approximately 1/3 points of the tube sheet.

The Contractor provides the lifting frame(s) as shown on the DEA drawings with the tube sheets at the time

of shipment from the Contractors facility. The Contractor ensures that each tube sheet has a handling label

attached.

6.4.7.1 Special Shop Tolerances

In addition to the standard Employer fabrication tolerances (Table 1 on Drawing Lead Sheet), special

fabrication tolerances are required for the tube sheets and alignment tools refer to tube sheet DEA drawings

in Appendix J. The following is a list of these special tolerances:

Flatness tolerance. Max waviness

Stiffener camber & sweep.

Hole diameter

Hole out of round

Hole side taper

Hole side surface finish

Dimensional between datum lines

6.4.8 Flue Gas Ducting

Ductwork is constructed by the Contractor as per the Employer’s design. All parts subject to deterioration

are easily accessible for inspection, maintenance or replacement.

The flues are all welded construction of steel plate not less than 6mm thick. Seal welding of ductwork plates

are performed on the inside of the ductwork and ductwork stiffeners are located on the outside of the

ductwork as per the Control of Plant Erection, Repair and Maintenance Welding Activities 240-56241933

standard.

All straightening vanes and gas distribution plates required are provided by the Contractor. Turning vanes

where required, are provided to minimize pressure drop in ducting.

Access doors are provided by the Contractor to permit access to all duct sections and on both sides of all

major items of equipment. The Contractor provides grab bars above all access doors. Internal ladders are




provided, by the Contractor, at access door locations where doors are located more than 900mm above the

flue floor.

The Contractor provides sampling points and test ports with safe access and platforms located at the fabric

filter inlet, fabric filter outlet and additional locations required for acceptance tests. The Contractor supplies

and installs sampling ports. Sample ports are 316 Stainless Steel materials. Necessary ports and flanges

are provided for the installation of the Contractor supplied instrumentation, such as thermocouples, pressure

transmitters etc.

The Contractor engineers and provides deflector plates to protect any dampers leading edges or protrusions

(such as thermocouple pockets or flue stiffeners) from erosion on the dirty gas side.

6.4.9 Flue Gas expansion Joints

The new expansion joints are able to withstand continuous operation temperatures specified for air heater

outlet and FFP excursion temperature. Internal flow liners are fitted to all expansion joints, by the Contractor,

to prevent erosion and dust ingress. The casing inlet and expansion joints are replaced, by the Contractor.

All expansion joints within the battery limits are inspected, by the Contractor.

Expansion joints deemed necessary to be refurbished to ensure plant integrity are included in the

Contractor’s scope of work. Where existing expansion joints are refurbished, the Contractor installs material

that is flue gas resistant, and suitable for the temperature conditions, and capable of absorbing axial, lateral,

torsional, and thermal movements during normal and transient conditions. The material at least has the

quality of PTFE impregnated material and is designed, by the Contractor, to the operating conditions of the

plant.

The Contractor is responsible for supplying the Plant and Material as well as Equipment required ensuring

plant integrity, this includes, but is not limited to, expansion joint belts, pillows (packing), shields, nuts, bolts,

flat washers, lock washers, retainer bars, and expansion joint frames.

Expansion joint includes shields. Expansion joints are provided in air and gas ducts where required to

accommodate thermal movement of the ductwork and equipment to which it is attached.

Expansion joints are selected to withstand normal design conditions on a long term basis and transient

temperatures and corresponding movements as determined by the Contractor. Fabric expansion joints are

preferred and consist of a fabric bellows element with sufficient membrane strength to withstand the gas

design pressure, external pressure loads and other design conditions, as applicable.

Expansion joints are designed for fabric replacement external to the ducting. The fabric is accessible from

outside the duct whenever possible.

Where installed in gas flues, fabric expansion joint assemblies include an internal flow liner (baffle) to limit

the entry of Fly Ash. The flow liner and fly ash seal is designed to prevent fly ash from accumulating in the




expansion joint cavity and protects the fabric from impingement by fly ash or other particulate matter in the

gas stream. The fly ash seal is capable of remaining flexible under continuous exposure to the anticipated

gas temperatures. Insulation pillows are provided at expansion joints where surface temperatures can

exceed 60°C, for personal protection. The design information for the Plant and Material to be supplied is

provided in the Technical Design Information contained in Appendix L. Site conditions and utilities are listed

in Appendix C.

The Contractor confirms dimensions onsite, where necessary, before completing the engineering design of

the expansion joints. The Contractor takes into account deflections as shown on the General Arrangement

and Design Erection Arrangement Drawings.

Workmanship and finish is equal to established practice in modern shops. All materials being worked have

clean surfaces. Fabricated members are neat and accurate. Reasonable tolerances are required for each

component.

6.4.10 Compartment Ventilations Fans and System


Technical Design Information sheets contained in Appendix M. Site conditions and utilities are listed in

Appendix C.

The Contractor is responsible for engineering design. The Employer may review, but will not approve, the

Contractor’s design to check compliance. It is the Contractor’s responsibility to ensure compliance with the

Employers Works Information.

The compartment ventilation fans are supplied, by the Contractor, with flanged connections for the

ventilation piping.

The compartment ventilation fans are arranged as one fan on each FFP casing. Each casing has one 100%

capacity ventilation fan with a cross-tie in the piping such that each fan acts as the 100% spare for the other

FFP casing (total of 2 fans for each Unit).

The ventilation fan wheels has backward-curved, air-foil shaped blades with one bearing on each side of the

wheel (the wheel shall not be overhung). Bearings are grease lubricated antifriction style. Bearings have a

minimum L-10 rating life of 130000 hours.

The fans are mounted on channel framed skids, with 1 fan per skid. The coupling between the fan and the

motor is designed, by the Contractor, such that the motor can be removed without disassembling the fan.

Fan isolation valves are knife gate type valves. Valves are supplied, by the Contractor, with air operated

actuators.

A limit switch that is waterproof, weatherproof, corrosion resistant and suitable for the operating environment

is provided, by the Contractor, for the open and closed positions.

The Contractor is responsible for supplying all Plant and Material required for a complete operating system.

This includes all valves and instrumentation required for the safe and dependable operation of the system. If




the Contractor thinks that additional Plant and Materials are necessary for system operation, the Contractor

price for this additional Plant and Materials and gives an explanation of why it is necessary to the Project

Manager.

6.4.10.1 Electrical

The Contractor supplies all motors required for operation of Contractor supplied Plant and Material. All

motors comply with the Employer’s standards for LV and MV motors; i.e. 240-57617975 and 240-50237155

respectively.

6.4.10.2 Control and instrumentation

The Contractor supplies a detailed description outlining the control philosophy. The write-up includes, but

not be limited to, start-up, shutdown, normal operation and special operating procedures. It also includes

all permissives and interlocks. Compartment ventilation fans are monitored from the plant DCS system.

All instrumentation provided must be of NEMA 4X enclosure type.

Refer to Section 6.5 and Appendix M for additional controls and instrumentation requirements.

6.4.11 Jib Crane and Hoists

The design conditions for the Plant and Material to be supplied are summarized in the Technical Design

Information contained in Appendix F. Site conditions and utilities are listed in Appendix C.

Workmanship and finish is equal to established practice in modern shops. All material being worked has

clean surfaces. Fabricated members are neat and accurate. Reasonable tolerances are required for each

component.

The Contractor selects/supplies and installs the jib crane required to lift equipment from grade to tube sheet

level as well as one jib crane for each compartment ventilation fan. The Contractor designs the support

structure for the compartment ventilation fans jib cranes. The location of these jib cranes are as per the

Employer’s GA drawings (0.61/97083, 0.61/97084, 0.61/97089, 0.61/97091, 0.61/97095 0.61/97853).

The Contractor selects the capacity of the jib cranes according to the weight of the Plant and Material to be

lifted to perform maintenance on the compartment ventilation fans. The Contractor submits the jib crane data

pages to the Project Manager for acceptance before procurement of the Plant and Material.

The Contractor provides one jib crane for the lifting of equipment from grade to tube sheet level as

specified in Appendix F, per FFP Unit. The Contractor also provides the jib cranes required for the

maintenance of the compartment ventilation fans.

The Contractor supplies a lifting crate for the lifting of FFP bags, fabric filter cages and other Plant and

Material for maintenance purposes. This is not the same crate as the crate for shipping of fabric filter bag

cages. The crate is manufactures of expanded metal mesh. The crate has provisions for lifting by the FFP

jib crane. The Contractor submits the design of the crate to the Project Manager for acceptance before

manufacturing/fabrication of the crate.




All hoists and jib cranes are locally operated.

6.4.11.1 Electrical

The Contractor supplies all motors required for operation of Contractor supplied Plant and Material. All

motors comply with the Employer’s standards for LV and MV motors; i.e. 240-57617975 and 240-50237155

respectively.

6.4.11.2 Painting and Preservation

All Plant and Material is protected by means of suitable paint systems, surface coatings, linings, or finishes

that are appropriate for the duty and environmental conditions typically found in a power station's emissions

control plant. As a minimum, all exposed non- stainless steel is coated as per Section 6.4.1, for painting and

coatings.

6.4.12 FFP pre-coating system

All Plant and Materials provided by the Contractor are new and is of composition, and physical properties

best adapted to the purpose in accordance with best engineering practice. The Contractor protects and

keeps clean all Plant and Material at all times from the weather and ensures that it is free from scale and

rust.

See the Employers design drawings for all Plant and Material and pipe sizes. All components are

fabricated from standard carbon steel pipe. For Carbon Steel pipe, see Employers specification CB-05.

Each spool is marked per the Employer drawings with the Ship Unit Part Number.

The Contractor performs shop inspections as required by the Contractor’s Quality Assurance program to

assure dimensional compliance of the fabricated spools with the design drawings.

The Contractor supplies all handling and lifting equipment necessary to safely load the ship assemblies onto

the transport carrier(s) without damage to the assemblies.

The Contractor supplies all temporary shipping bracing and tie-downs as needed to safely transport the

spools to Site.

Painting or coating is to be shop prime coat inorganic zinc (0.0508 – 0.0760 mm DFT( 2-3 mils)). Surface

prep is according to SSPC SP6.

Identifying marks consisting of the Employers ship unit part number and the Employers Contract number is

shown on all shop sketches and is clearly marked on all pipe spools, by the Contractor.

Pipe spools are marked with white indelible lead free paint in a readily visible location with minimum 50 mm

high lettering.

The Contractor supplies a system of which the materials meet the requirements or specifications as per the

design drawings. Where the Contractor wants to use a different material the Contractor submits a proposal to

the Project Manager for acceptance before manufacturing and installation.




The applicable design drawings are as follow;

0.61/97751 (B&W Dwg No. B0331642) Design Arrangement – Tutuka Unit 6 FFP – Casing A & B –

Pre-coat Piping – General Information & Key Plan


Pre-coat Piping – Item Mark Number Indexes


Pre-coat Piping – Plan views


Pre-coat Piping – Section 001-001


Pre-coat Piping – Sections & Views

The Contractor supplies pre-coat material according to the Fabric Filter Plant Bag Standard (240-53113965).

The pre-coating material is hydrated lime. The Contractor coats the fabric filter bags with pre-coating material

after installation of the filter bags and during commissioning of the pre-coating system.

When introducing the pre-coat material, feed the material consistently and avoid overfeeding that could result

in settling out of the product in the hopper. Pre-coat material is added to achieve coverage equivalent to 150

to 200 g/m2 of filter bag area. It is estimated that 2 kg per bag will achieve 150 to 200 g/m2.

6.4.13 FFP Hoppers

The Contractor performs the FFP hopper modifications as per the Employers drawings;

0.61/97159 (B&W Dwg No B0316630) Tutuka Power Station Unit 6 Fabric Filter Plant Casing A&B

FFP Hopper Modifications General Info, Notes & Dwg List Field Alterations


FFP Hopper Modifications, Key Plan

0.61/97161(B&W Dwg No B0316632) Tutuka Power Station Unit 6 Fabric Filter Plant Casing A&B

FFP Hopper Modifications & Views Field Alteration


FFP Hopper Modifications, Sections & Views

The modifications done on the hoppers are planned to take into account the interfaces with Others working

on the hoppers. The major interfaces are the installation of aeration pads in the hoppers and a vent pipe from

the DHP pressure vessels into the FFP hoppers.

The Contractor is aware that Others are working in and below the hoppers, therefore the Contractor makes

the necessary safety considerations for the protection of Others. Others will require access to the hoppers

while the Contractor carries out work above. It may still be required of the Contractor to construct two bridge

scaffoldings per casing of suitable width to suitably protect Others from falling objects and give Others

access beneath the hopper.

The Contractor designs, manufactures and installs a blanking flange, to be temporarily bolted to the hopper




outlet flange, once the DHP has been disconnected and the hoppers has been washed. The purpose of the

blanking flange is to prevent debris from falling into the working area of the DHP, by Others.

The Contractor installs the instrumentation in the FFP hoppers in the areas as indicated on the Employers

drawings. The Contractor determines the instrument installation and connection details for the hopper

continuous level transmitter and makes use of document 474-9233 as the guideline (A guided wave radar

was considered by the Employer during the design phases as per the drawing 0.61/97941). The Contractor

ensures that the instrumentation can be reached for commissioning, maintenance and normal operation from

existing or newly installed walkways and platforms. Where the Contractor believes that the location of the

instrumentation must be moved for ease of access and/or practical reasons, the Contractor notifies the

Project Manager. The Project Manager accepts the changes before the Contractor installs the

instrumentation. Due to this installation the existing agitating chains in the hoppers are removed by the

Contractor.

The Contractor inspects the existing ESP hopper doors (0.61/8993), the Contractor makes sure that the

hopper doors are fit for purpose. The Contractor removes the existing interlock on the ESP hopper doors, but

retains the existing padlock system on the hopper doors.

Where the existing Employer drawings are unclear the Contractor inspects the site and confirms the

information in question.

The Contractor inspects the existing hopper heaters and ensures the hopper heaters are fit for purpose. If the

hopper heaters are found to be unfit the Contractor replaces the hopper heaters.

The Contractor performs the hopper heater cable routing, installs JB’s and instrumentation as per Employers

design.

6.4.14 FFP Access Doors (Compartment and Flue)

The Contractor is responsible for engineering design. The Employer may review, but will not approve, the

Contractor‘s design to check compliance. It is the Contractor’s responsibility to ensure compliance with the

Employer’s Works Information.

Table 11 : FFP Access Door Supply Quantity

Quantity Hinge Orientation Status

40 per Unit All doors same side FFP Compartment Access Door

4 per Unit All doors same side Flue Access Door

The Contractor provides access doors with means to lock in the open position to prevent accidental closing

with maintenance personnel inside the FFP compartments and flues. Doors are provided with external

latches and tightening devices which allow for gasket shrinkage and maintaining zero leakage.

The Contractor provides compartment access doors with an internal expanded metal screen door that can

remain closed when the outer door is open, to allow ventilation of the FFP compartments. The expanded




metal screen door can be locked open on the inside of the FFP compartment when personnel are performing

maintenance in the FFP compartments.

The Contractor performs the manufacturing and installation as per the Employers drawings below;

Drawing number Drawing title

0.61/97904Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Key Plan and General Notes

0.61/97905Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Left Handed General Assembly

0.61/97906Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door RightHanded General Assembly

0.61/97907Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Left Handed Door Frame Assembly and Details

0.61/97908Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door RightHanded Door Frame Assembly and Details

0.61/97909Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Left Handed Door Details

0.61/97910Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door RightHanded Door Details

0.61/97911Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Support Arm Details

0.61/97912Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Left Handed Screen Door Details

0.61/97913Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door RightHanded Screen Door Details

0.61/97914 Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Seal Bar Details0.61/97915 Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Hinge Pin Details0.61/97924 Tutuka Unit 6 Fabric Filter Plant Casings A and B Compartment Door Insulation Cover

6.4.15 Fire Protection

The Contractor supplies, tests, commissions and installs fire extinguishers at the entrance to the outlet

compartments. All fire equipment supplied is in accordance with the following standards:

240-54937439 Fire Protection/Detection Assessment Standard

240-56737448 Fire Detection and Life Safety Design Standard

240-54937450 Fire Protection & Life Safety Design Standard

6.5 Control and Instrumentation engineering Works

6.5.1 Introduction

The Contractor refers to Appendix D (9) for the portion of the scope to be considered as a takeout option

during the tendering process,




The C&I system design is completed by Others.

The works complies with professional engineering practice and standards for fossil fuel power plants, and is

designed for the environmental conditions prevailing at Tutuka Power Station Site.

The Contractor implements the FFP C&I system design in the existing unit 4 - 6 ABB DCS/Marshalling

control cubicles as per the Employer’s Design. The Contractor implements Cleaning Air Equipment Plant C&I

design in the outside plant Yokogawa DCS/Marshalling control cubicles by expanding the DCS (Thus the

new Cubicles are provided).

The Contractor ensures that the C&I FFP interface provides for total automation of the FFP through the Unit

DCS. The FFP C&I solution provides for interlocks to prevent incorrect operation of the FFP and the

cleaning air equipment plant system by the unit controller or operator.

The detailed scope of supply for the works is defined by a combination of performance, functional and Plant

and Materials specifications such that a complete functioning system is provided. The Contractor informs the

Project Manager of all changes required to the existing operating, maintenance and control philosophies and

obtains his acceptance prior to making these required changes to the existing systems.

The Contractor is required to provide information and documentation in accordance with the requirements

set out in this Works Information.

The basis for the supply of all documentation relevant to the different project stages is stated in the VDSS.

The Plant and Material covered by this Works Information is designed, fabricated, inspected and tested in

accordance with the applicable codes and standards listed in this Works Information.

These codes and standards set forth minimum requirements which may be exceeded by the Contractor, if, in

his judgment and with the Project Managers acceptance, superior or more economical designs or Materials

are available for successful and continuous operation of the Contractors equipment as required by this

Works Information.

The Contractor warrants that all Plant and Material, and services furnished, comply with all governing country

and local laws, regulations and codes and all applicable specifications and standards.

In the event of any apparent conflict between standards and codes as referenced in this Works Information,

the Contractor refers the conflict to the Project Manager for written resolution.

Plant and Material or components of a prototype design will be rejected, regardless of price offered.

The Contractor includes in the Deviation and Exceptions schedule - Appendix A of his proposal, a statement

that the Plant and Material offered is in full conformity with the Works Information except as noted and listed

specifically in Appendix A.

If there are no Deviations or Exceptions noted in Appendix A, it will be interpreted that the Plant and Material

to be furnished, by the Contractor, will be in strict accordance with the Works Information.

Any exception to the Works Information deemed by the Employer to be of a major nature will constitute




grounds for rejection of the proposal. The Employer reserves the right to reject any exception which

appeared or existed in any part of the proposal. If deviation to this Works Information is required, the

Contractor provides justification for the deviation.

6.5.2 Control and Instrumentation

The works includes the decommissioning of the existing ESP control systems and interfaces. The

Contractor decommissions software and network systems, logics and interlocks for the ESP systems.

The Contractor procures, installs, optimises, performs capability tests and commissions the FFP and FFP

pulse air C&I system (including field equipment, cabling and related Plant and Materials).

Appendix D (9) details the Tutuka Instruction to Tender for the takeout option of the C&I portion of the scope

to be provided for by the Contractor during the tendering process.

The portion of the Control and Instrumentation of the works includes;

Field Equipment and Cabling Procurement, Installation, Commissioning and Testing.

Field Equipment and Cabling includes as a minimum control devices, actuators, instruments,

junction boxes, cable racking/trunking/conduits, instrument and control cabling and a e for each

cleaning air compressor.

Field Equipment and Cabling Transportation and Storage

New MIMICS design with control options in the existing HMI (Operator terminal) in existing OPCR

and the unit control rooms.

The Contractor reconfigures the networks associated with the ESP rapper controllers to allow the

system to work after the existing ESP equipment from a unit has been removed.

The Contractor implements the control system(s) and philosophies designed and developed by

Others for the control, protection interlocking and monitoring of the cleaning air equipment plant

system in the outside plant DCS. The Contractor is responsible for functional integration of cleaning

air equipment plant system operation and logics with outside plant DCS.

The Contractor liaises with Others to implement FFP operating, control and protection philosophies

developed by Others in the new DCS system in Unit 1 – 3. The Contractor implements FFP

operating, control and protection philosophies developed by Others in the ABB DCS system in Unit

4-6. The Contractor is responsible for optimization of the FFP and associated plant areas.

The responsibility for the correct operation and implementation of these philosophies in the DCS

remains the responsibility of the Contractor.

The Contractor is responsible for civil work which is required as a result of the C&I portion of the

Works Information.

Earthing and lightning protection of all C&I equipment within the Contractor’s scope of work.

If applicable, provision of all software, licensing and copyright agreements to enable the operation of

the system(s) as specified in the Works Information.

Special tools and programming devices which are required to maintain the field devices and control

systems provided by the Contractor.




Documentation which include updated operational procedures (affected by change/modification),

product manuals, C&I system configuration documentation and maintenance procedures.

Interface details which will be required for the integration of the FFP and the cleaning air equipment

plant system into the unitised control system and the common plant control system respectively.

Provision and installation of all trunk cabling and associated cable racking/trays in Unit 4-6 up to the

DCS/Marshalling cubicles including terminations in the cubicles.

Unit 4 - 6 LV switchgear interfaces and control wiring from LV switchgear to the DCS.

Integrating the loop diagrams, as per Employers design, in the system is by Others in Unit 1 - 3 and

by the Contractor in Unit 4 - 6.

Reconfiguring the system to include the new FFP information in Unit 4 - 6 to the existing PIS for data

storage and long term information.

The Contractor is responsible for the optimisation and capability tests of these systems

Control wiring from IO panels to MV and LV Switchgear for the cleaning air equipment plant.

Cleaning air equipment plant system PLC’s interfaces to the outside plant DCS, the interface shall

allow for control, protection and status monitoring in the outside plant DCS

Overall cleaning air equipment plant control system integration into the outside plant DCS. The

Contractor optimizes and performs capability tests of this system.

6.5.3 Control System

The Contractor implements the control, operating philosophies and SRS - E211426 (Including control logic

diagrams) as designed by the Employer in Unit 4 - 6 DCS and the new DCS (by Others) in Unit 1 - 3.

6.5.3.1 Unit 1 - 3 Control System Requirements

FFP scope is included in Tutuka Unit 1 - 3 C&I boiler/turbine auxiliary control system replacement project.

The control system is as supplied by Others in the Tutuka Unit 1 - 3 C&I boiler/turbine auxiliary control

system replacement project.

The Contractor implements the FFP C&I design up to the junction boxes (including the procurement and

installation of the junction boxes) and interface with Others to realise a complete functional operating control

system.

The control and operating narratives (including functional logic drawings) for the FFP system is made

available, by the Employer. The Contractor provides for the engineering, including software engineering

(programming) designs of the functional logic drawings and control philosophy as per the Employers design.

6.5.3.2 Unit 4 - 6 Control System Requirements

The FFP control system design and Plant and Material, as per Employers design, are in accordance with the

existing ABB P14 DCS installation specifications and requirements.

The Contractor implements the FFP control system design in the existing Unit 4 - 6 ABB DCS/Marshalling

control cubicles and provides in writing the reserved spare capacity (Hardware and Software) left after




implementing the FFP design. The Contractor provides in writing the spare capacity absorbed as a result of

the modifications, on the part of the Employer.

The Contractor provides for the engineering, including software engineering (programming) designs of the

functional logic drawings and control philosophy in the DCS as per the Employers design

6.5.3.3 Outside Plant Control System Requirements

Common plant equipment such as the cleaning air equipment plant system is interfaced to the outside plant

DCS.

The Contractor implements the cleaning air equipment plant control system C&I design in the outside plant

Yokogawa DCS/Marshalling control cubicles by expanding the DCS, thus new cubicles are catered for by the

Contractor.

The C&I system design for the outside plant is in accordance with the existing outside plant YOKOGAWA

DCS installation specifications and requirements.

The Contractor provides and demonstrates the recovery procedure for the PLC/Controllers associated with

the cleaning air equipment plant.

The Contractor provides the Project Manager with two Copies (Soft copies) of backups after commissioning

of all the PLC related systems within his/her scope.

6.5.3.4 Pulse Air Headers Control

Sequencer control cards are housed in NEMA 4X Stainless Steel enclosures mounted on pulse

header.

The immersion solenoid valves must be equipped with terminals for connection of the wiring

between each immersion valve, and the sequencer control card. “Pigtails” or butt splice connections are

not acceptable. The Contractor provides a common NEMA 4X Stainless Steel wire way mounted and

supported from each header with electrical sealtite conduit connections to accommodate the wiring to each

immersion valve.

6.5.4 Boiler Protection System (BPS)

The Contractor ensures that the protections for the FFP system are in line with 240-56241288, Rev 1 the

standard for Fossil Fired Boiler Protection Functions: Requirements and Control Measures.

The hardware as well as software changes to the boiler protection system are performed by the Contractor in

Unit 4 – 6 and by the Others in Unit 1 – 3. The changes include accommodation of the new protection

requirements of the works as well as changes to the protection system’s online self-testing functions.

6.5.5 Human Machine Interface (HMI)

A fully functional HMI that includes control functionality, indication, alarming, trending, on-line plant

performance information and event recording is provided by Others in Unit 1 - 3 and by the Employer in Unit

4 – 6 and common outside plant control system.




The Contractor designs and integrates the new FFP mimics into the existing Unit 4 – 6 HMI in the control

room for control and monitoring of the FFP, including the new dampers / drives provided with the FFP.

The Contractor designs the new FFP mimics and interface with the Others in Unit 1-3 to integrate the mimics

into the HMI screens in the Unit Control Room.

The Contractor designs and integrates the new cleaning air equipment plant mimics into the existing HMI in

the OPCR for control and monitoring of the cleaning air equipment plant.

It is the Contractor’s responsibility to ensure the correct implementation and integration of the HMI mimic

designs in Unit 1-6 and the common outside plant control system.

6.5.6 Plant Information System (PIS)

The Contractor caters for the new inclusion of FFP signals/tags in the existing PIS by configuring the system

in the Unit 4 – 6.

The Contractor interfaces with Others in Unit 1-3 to ensure that new inclusion of FFP signals/tags in the PIS

is implemented correctly.

The Contractor ensures that the system is configured to include the new signals/tags for the cleaning air

equipment plant in the existing PIS (Outside Plant).

6.5.7 Data Acquisition

Data acquisition is provided for processing of signals from field mounted transmitters and any other field or

interfacing devices. The data acquisition monitors the condition of the measurements, and faults reported by

the transmitters. Signal distribution and transmission to other systems requiring the measurements and fault

data, are done as part of the data acquisition. The data acquisition is part of the respective automation unit.

Time stamping is done at the lowest level of the relevant DCS control system and as close as possible to the

source of the signal. Time stamping with a time resolution of one millisecond is achieved.

6.5.8 Simulator Plant Requirements

Unit 1-6 will have an ABB P14 DCS, this is after it was confirmed that Unit 1-3 C&I project will install an ABB

P14 DCS. This means that an existing Unit 4-6 Simulator Plant will be modified to be Unit 1-6 Simulator.

The first unit to get an FFP will be from unit 4-6 and the plant operators are required to be trained on the

plant simulator.

The Contractor provides for the modification and updates to the Unit 4 - 6 Simulator to include the new FFP

system.

The Contractor provides all the information required for the modelling of FFP System in the existing Unit

plant simulator.

The updating of the simulator includes as a minimum, the modelling software of the FFP System and the

control system. The Contractor caters for the removal of the ESPs in the existing simulator.




6.5.9 Cleaning Air Equipment Plant System Design

The Contractor is responsible for interfacing the Cleaning Air Equipment Plant controls from the junction

box/enclosures/panels in the Cleaning Air Equipment Plant Building (or Compressor House) to the outside

plant DCS/Marshalling cubicles. Compressors are supplied with their own controllers/PLC as a package on

a skid. It is envisaged that the driers are supplied with their own controllers. The Contractor ensures that

these controllers are correctly interfaced to the DCS.

The Contractor ensures that protection and control signals between the Cleaning Air Equipment Plant and

the FFP controls are hardwired.

A redundant solution for the common controls and instruments is considered and catered for in the design,

this is critical for always making the controls and information available to the operators.

All hardware, software and control network redundancy with regard to the controls and power supplies are

configured to match that of the redundant mechanical process.

Sequential starts for the dryers and compressors are done and implemented on a single LCS (Local Control

Station) located at the compressors. The controllers/PLC in the Cleaning Air Equipment Plant building is

designed to operate at ambient temperatures of 40 Degree Celsius.

The Contractor supplies and installs all of the instrumentation and cabling up to the junction boxes (including

supply and installation of junction boxes). Field instrument cabling to these junction boxes runs through

conduits. The field design follows the requirements of the outside plant DCS system.

The PLC design provided by the Contractor provides for signal isolation between the DCS and the PLC. The

PLC software is written in a clear and logical manner. The PLC is provided with related programming tools

and required programming software. The PLC makes provision for disturbance reporting of field equipment

as well as PLC to the DCS. The control interface for the PLC meets the standard control interface templates

utilised by the DCS control system.

The cleaning air plant equipment system design provides for Local Control Stations (LCS) at each

compressor (HP Design). These Local Control/HMI Stations are access controlled, i.e. no personnel is able

to operate or manipulate the FFP cleaning air plant equipment system or a component thereof without

access rights and permission from the Operating Department.

6.5.10 Field Equipment and Cabling Requirements

The Contractor supplies all the required field equipment and cabling for the works.

The Contractor terminates the field cabling in the junction boxes and enclosures such as a splitter box.

The Contractor ensures that:




All field instruments and equipment are installed in accordance with the requirements of the Field

Instrument Installation Standard, 240-56355754 Rev 1.

Temperature measurement systems installations are installed in accordance with the Employer’s

standard 240-56355888 Rev 1.

Pressure measurement systems installations are installed in accordance with the Employer’s

standard 240-56355843 Rev 1.

The requirements for junction boxes, local control panels, and local control stations are in

accordance with the Employer’s standard 240-56355815 Rev 1, Field Instrument Installation

Standards: Junction Boxes and Cable Terminations.

Cable racks control and power cabling conforms to the requirements of the standard 240-56227443,

Rev 1

The Contractor proposes which of the existing cable tray/rack/manholes are re-used in his design. The

Contractor needs acceptance from the Project Manager to re-use existing cable tray/racks/manholes.

The Contractor shields and protects all cabling exposed to direct sunlight with appropriate covers and

ensures that field cabling running on racking are protected against UV (Ultra Violet) light.

Instrumentation and field equipment (such as actuators and transmitters) supplied by the Contractor supports

standardisation on existing instrumentation (and actuators) in the outside plant and Unit 4 - 6, as well as

instrumentation which will be provided by the Others on Unit 1 - 3.

Additional protection hoods and enclosures must protect those transmitters situated outdoors or in adverse

environments.

Instrumentation cabling between the instrument and the junction box runs inside the conduit (for a single

instrument), trunking is used where there is accumulation of a number of field cables. Cable trays and

racking are only allowed as trunk cabling supports between the DCS cubicles and the junction boxes.

The Contractor provides all necessary scaffolding for the erecting and installation of cabling and racking.

6.5.11 Power Supply Requirements

All instrumentation is loop powered from the DCS. The Contractor utilises the bulk supply from the existing

UPS to supply all the equipment such as pulse sequencers and leakage detectors as indicated by the

Employer’s design (See Cable Block Diagrams).

The Contractor is responsible for safety clearances of power supply interfaces that forms part of the

Contractor’s design

6.5.12 Impulse Piping and Accessories

All impulse process piping and accessories adheres to the requirements in 240-56355754 Rev 1, Field

Instrument Installation Standard.




6.5.13 Licences

All licenses required by the Employer covering the Plant, standard software and application software, forming

part of the works, are included by the Contractor.

On sectional completion Contractor provides a software register with a contents reference to software,

software revision, operating system and reference to operating system AKZ.

Licenses for the Plant and software provided include the Contractor’s Subcontractor or third party licenses

for the life of the control system and are site licensed for use at Tutuka Power Station.

The Contractor provides all upgrades of software and the associated licenses throughout the duration of the

Works.

6.5.14 Process Control and IT works

Human machine interface (HMI) requirements are as detailed in section 6.5.5.

Plant Information System (PIS) requirements are as per section 6.5.6.

Time synchronisation of the added hardware is the responsibility of the Contractor for Unit 4-6 and common

plant. For Unit 1-3 it is the responsibility of Others.

The Contractor provides virus protection programs/philosophies for Plant and Materials that is exposed to the

risks and complies with cyber security standard for OT (240-55410927).

The Contractor retrofits plant with the latest version of Software and Firmware during the execution of the

works.

6.6 Cleaning Air Equipment System

The FFP’s are supplied with cleaning air from its own dedicated cleaning air system using compressors and

air dryers. Each cleaning air compressor and air dryer is supplied as a packaged unit together with data

sheets and performance curves. The cleaning air equipment is installed in the Tutuka FFP and DHP

compressor house, by the Contractor. The Tutuka FFP and DHP compressor house is provided by Others.

The Contractor includes a list of exceptions and/or clarifications to this Section, as per Appendix A. This list

of exceptions includes the Works Information section as reference number, the requirement in question, and

a detailed explanation of the deviation or clarification. If the Contractor has questions regarding the intent of

a requirement, the Contractor contacts the Project Manager. No deviation from this Works Information and its

referenced documents is permissible without documented acceptance from the Project Manager. In the

event of conflicts or discrepancies within the Works Information, the Contractor notifies the Employer for

resolution. The Contractor is understood to be in full compliance with all requirements of this section unless

exceptions are noted, by the Contractor at tender in Appendix A.


prudent industry practice. The Contractor and Contractor’s Subcontractors perform the works in compliance




with legislation, rules and regulations, applicable national and international engineering, environmental,

construction, health and safety and other applicable standards. All units are in SI units.






Where the referenced codes and standards contain recommendations in addition to requirements, the

recommendations are considered as requirements and are followed, by the Contractor, unless stated

otherwise.

6.6.1 Pipe spool fabrication

Where required, the Contractor uses spool pieces to complete the respective piping systems. The Contractor

fabricates, erects, supplies, installs, cleans, tests and commissions spools pieces and ensures that the spool

piece meets the design requirements as per the Employers design for the corresponding piping system

where the spool pieces is used.

Where galvanising is applicable, the Contractor fabricates, erects and installs spool pieces on site after

which it is dismantled and sent for galvanising. Once galvanising is complete the Contractor installs and

commissions the spool piece along with the piping system.

Publications of the following agencies forms part of the Works Information to the extent specified therein. All

references to their publications are to the latest issue of each, together with the latest additions and/or

amendments thereto, as of the Contract Date, unless otherwise indicated. This list is not all-inclusive and

does not relieve the Contractor from complying with all applicable codes including those at the state and

local level.

All Plant and Material provided are new and of kind, composition, and physical properties best adapted to

their several purposes in accordance with best engineering practice. Plant and Material shall at all times be

kept clean and protected from the weather and shall be free from excessive scale and rust.

Approved Plant and material meeting the requirements, or better, of the appropriate specifications, where

available, of the American Society for Testing of Materials or other recognized standard shall be employed.

6.6.1.1 Fabrication Scope of Work

The Contractor supplies all pipe, fittings and flanges materials and fabricate into shop pipe spools as

shown on the Pipe design and/or Isometric drawings.

The Contractor supplies all Plant and Material, detailing, shop labour etc. as needed to fabricate the

following FFP piping systems:

Pulse Air Pipe System Instrument Air Pipe System Pulse and Instrument Air Cooling Pipe System




Compartment Ventilation System Bag Disposal Chute System

See the Employers design drawings for all Plant and Material and pipe sizes. The compartment ventilation

system and the bag disposal chutes are spiral weld pipe systems. The pulse air system is carbon steel pipe

(CB05).

For Carbon Steel pipe, see attached CB-05. For Spiral Weld pipe, refer to drawings and/or the piping

specification CB-07 in the pipe specification manual in Appendix V.

Each spool is marked per the drawings with a Ship Unit Part Number.

The Contractor performs shop inspections as required by a Quality Assurance program to assure

dimensional compliance of the fabricated spools with the design drawings.

The Contractor supplies all handling and lifting equipment necessary to safely load the shop assemblies onto

the transport carrier(s) without damage to the assemblies.

The Contractor supplies all temporary shipping bracing and tie-downs as needed to safely transport the spools to the plant site.

6.6.1.2 PAINTING /COATINGS

Piping including fittings and flanges are hot dip galvanised. Galvanising is done in accordance with SANS

121.

6.6.2 FFP Pulse Air Headers

The design conditions for the pulse air headers are summarized in the Technical Design Information

contained in Appendix P. Site conditions and utilities are listed in Appendix C.

The Contractor supplies the following Plant and Materials;

Air header with support attachments for Control Panel

Welded brackets for tank support (attach to supporting structure)

Integral Diaphragm/Pulse Valves

Integral Solenoids

Flexible connectors with clamps

Sequencer control cards with latching relay

Instrumentation

Wiring

Supporting structure

Erection

Blowpipes

Power supply and control input wiring to sequencer




Quantities are per Appendix P. If the Contractor thinks that additional Plant and Material is necessary for

system operation, the Contractor quotes this additional equipment and supplies an explanation of why it is

necessary to the Project Manager.

Pulse air headers are fabricated to ASME Section VIII Division 1 and is code stamped.

The pulse valves are immersion style. The pulse valve centre to centre spacing is as per Appendix P.

Tolerances measured to the adjacent valves does not exceed centreline spacing ± 1.5 mm. Tolerance from

header centreline in the vertical direction is ± 1.5 mm and no more than ± 3 mm between valves. Each of the

pulse valve outlets on an air header is connected to a blowpipe with a flexible connector.

Pulse valves are mounted to the pulse air header such that the vent port is pointing down. For header

arrangement where this is not possible the vent air is directed downward using an elbow to prevent water

entry and for safety.

Flexible connectors are provided to separate the blowpipe from the pulse valve piping. 305mm

long Parker Titan Hose (Number SS-269) is used. If the Contractor wants to use another material the Contractor

submits the proposal to the Project Manager for approval before using that material.

The flexible hose complies with the following specifications:

Temperature range -40 °C to 54 °C

Pressure 689 kPa spikes (spikes are <300 ms, 6 times per hour)

Maximum operating pressure 689 kPa

Normal operating Pressure negative 10 kPa

Conveying Fluid compressed air

Hose I.D. 89mm

The flexible hose is suitable for outdoor use and is UV rates. The actual size of the flexible connector may

vary depending upon the size of the pulse valve piping. The joint laps nominally 50 mm at both ends.

Standard T-Bolt hose clamps are used by the Contractor. Ideal 30010 Series/ Tridon 813 Series or Project

Manager approved equivalent is provided to seal the flexible connector to the mating pipe sections. Two

clamps are required for each hose. Flexible connectors separate the blowpipe from the pulse valve piping.

The actual size of the hose clamp may vary depending upon the size of the pulse valve piping and thickness

of the hoses.

Solenoids are mounted on each pulse valve for ambient temperatures greater than -40C. For

ambient less than -40C, solenoids are mounted in NEMA 4X heated boxes and piped to the individual

valves with stainless steel tubing. Tubing is installed and routed using industry best practices. Tubing bends

are made without reducing the internal diameter of the tubing; any flattening, kinking or wrinkling of the

bends is unacceptable.




The pulse air system is set up for online cleaning of filter bags. Air headers are sized to actuate the number

of pulse valves at one time as listed in Appendix P.

Digital sequencer control cards are provided for control of the pulse valves. One (1) digital sequencer

control card per air header is required. Each sequencer control card output quantity must be equal to or

greater that the number of pulse valves. The outputs are capable of firing two (2) solenoids. The sequencer

pulse duration is adjustable between 30 msec to 300+ msec and the time between pulses a r e

adjustable from 1 to 60+ seconds via digital input. The sequencer cards are controlled by DCS. Sequence

firing order is as per Appendix P.

Each sequencer card supplies a sequencer complete signal, when the last valve pulses. This signal is

adjustable with 200 msec minimum pulse duration. The signal can be supplied either by the sequencing

card or directly from the signal for the last pulse via a latching relay. The latching relay (if required) shall

be an Allen-Bradley Series 700-FS relay or Project Manager approved equivalent.

The pulse air headers a r e completely shop assembled and tested, by the Contractor. This includes all

wiring, tubing, valves etc.

The header size is determined by using an initial header pressure of 552 kPa. The volume of air used is

determined by the number of valves pulsed on a header at the same time. The pressure should not fall

below 379 kPa (+172/-20). No allowance for incoming air is used (i.e. isolation valve closed). Blowpipe

holes sizes are as per Appendix P.

Pulse Headers are supplied with flat end caps.

All piping, flanges, and valves are as per ANSI or equivalent standards.

Header, valves, piping etc. are suitable for outdoor service.

Pipe dope is not allowed to be used to seal threaded connections. If sealing of the threaded connections is

required, Teflon tape is used.

Valves are mounted to the header such that the vent port is pointing down. For header

arrangements that do not allow the port to face down, the vent air is directed downward using an elbow to

prevent water entry and for safety.

A minimum of two anti-rotation bars a r e located 20 degrees from horizontal as shown in drawings

included in Appendix P. The exact location is determined upon submittal of the Contractor’s drawings.

The pulse air header discharge piping is oriented as per Appendix P.

6.6.3 Pulse air header expansion joints (flexible hose)

The Pulse Air Header Expansion Joints will be used in a Fabric Filter Plant installation for the Eskom Tutuka

Power Station.

Hose meeting the specifications listed below is used, by the Contractor. The expansion joint laps nominally

50 mm at both ends. The pipe ends need not be provided with barbs. The hose length is 300 mm, if

available, the Contractor, obtains quotes for hose cut to 300 mm length, but if this isn’t possible, the




Contractor supplies standard lengths to be field cut to 300 mm length. The Contractor ensures that hose size

matches the size of the pulse valve discharge, J-pipes and extension pipes.

Table 12 : Pulse Air Header Expansion Joint (flexible hose) Specification

Description Units RequirementExposure - Outdoor service – rated for UVFluid Handled - AirHose inside surface - Silicone linedTemperature, Min. C -40

Temperature, Max. C 54Operating Pressure, Maximum

kPaG 690

Operating Pressure, Normal

kPaG - 10

Pressure spikes kPa 690 spikes (spikes are < 300 milliseconds

every 8 minutes)

Size mm Section 6.6.2

A hose clamp is used to seal the ends of the expansion joint to the mating pipe sections. Use heavy duty T-

bolt standard clamp, sized for outside diameter (O.D.) of hose to fall near the mid-range of clamp.

6.6.4 Blow pipes and J-pipes


Technical Design Information sheet contained in Section 7.

Shop QC inspections as required to assure dimensional compliance of the fabricated parts with the

reference drawings in Appendix J.

All inspections as required by the Contractor’s Quality Assurance program.

The Contractor ensures safe loading of the blowpipe / J pipe ship units onto trucks without damage to the assemblies.




6.6.4.1 Fabrication Requirements

Plant and Materials are procured and controlled in accordance with the Contractor’s Quality Assurance

program or QCP. Plant and Materials are as listed on drawing lead sheets.

All work is performed, by the Contractor, in strict accordance with the DEA drawings and the Works

Information. The workmanship and finish of everything is equal to the best practice in modern fabrication and

manufacturing.

Plasma and laser cutting of pipes, blow holes, end flanges and supports is permitted. All blowpipe insides

must be free of debris, burrs, spatter and any foreign material left over from the cutting / welding / drilling




processes. The Contractor swabs and cleans the inside of blowpipes.

Blowpipe material standard is SANS 62-1 (Medium Class) structural tubing (3.2 mm wall), J pipe and

extension pipes are SANS 62-1 (Heavy Class) structural tubing (3.9 mm wall). Any purchased tubing is

checked for straightness prior to fabrication, by the Contractor. Any bow is set in the vertical up or down

position.

Preferred method of creating the J pipe bends is by forming the radius by a cold bending operation. After

bending, the ends of J pipes are checked for levelness, especially at the flange ends, to ensure consistent

welding of end flange to J pipes. Uneven ends are reworked (milled or grinded down), by the Contractor, until

all ends are level.

Alignment jigs and fixtures are recommended for consistency in assembling/welding the ship units.

Any shop splices, if required, are accepted by the Project Manager first and then indicated on the detail

drawings. Shop splices are full penetration welds.

Datum lines are shown on the DEA drawings and are marked on all J Pipe ship units, by the Contractor.

All blowpipes / J pipes / Extension pipes are unpainted and free of loose rust, mill scale, etc.

Deviation from the reference drawings or this Works Information requires written approval from the Project

Manager. This includes, but not limited to, requests for substitution of materials, weld details, structural

shapes, and plate sizes. Any ambiguities, errors or inconsistencies noted by the Contractor are reported in

writing to the Project Manager for resolution prior to material procurement and fabrication.

All welding details are in accordance with AWS D1.1, unless otherwise approved in writing by the Project

Manager. Weld symbols is as per AWS A2.4

The Contractor assures proper fit of the fabricated components. All costs associated with any field

modification to the fabricated components necessary to achieve the as-erected tolerance is assumed by the

Contractor.

The Contractor dimensionally verifies that the completed components are within the tolerances specified on

the DEA drawings. The measurements are recorded. Any correction needed to bring the fabricated

component into compliance is done prior to shipment at the Contractor’s expense without schedule relief.

Drafting practices employed, by the Contractor, conforms to AISC and AWS requirements. All work is neat

and legible, and equal to the best in modern drafting practice.

6.6.4.2 Special Shop Tolerances

In addition to the standard fabrication tolerances, special fabrication tolerances are required for the

blowpipes, J pipes and alignment tools. The following is a list of these special tolerances. See DEA drawings

(Appendix J) for all tolerances:

Pipe ends must be cut square. Length tolerance for all pipes is +/- 1.5 mm

Flange face must be square within +/- 0.795 mm across the face relative to the pipe axis.

Maximum bow of blowpipe assembly shall not exceed 3 mm




Maximum camber & sweep of channels not to exceed 3 mm

Flange face to any blowpipe hole shall not exceed +/- 1.5 mm

J pipe datum to any pipe centreline not to exceed +/- 1.5 mm

Angular deviation of blowpipe holes from true vertical relative to the end flange holes does not

exceed 0.5 degrees.

To achieve the specified as erected component tolerances, the Contractor must carefully dimension

component parts, specifying part tolerances as required.

6.6.5 Piping Supports

6.6.5.1 Piping Supports Design

Standard type pipe support components conform to ANSI/MSS SP-58, “Pipe Hangers and Supports-

Materials, Design and Manufacture”.

Design is in accordance with the applicable local codes and regulations and the applicable sections of

American codes and industry standards including:

South African National Standards (SANS)

o B31.3 Process Piping

Steel Structures Painting Council (SSPC)

Manufacturers Standardization Society (MSS)

o SP-58

o SP-69

American Welding Society (AWS) Structural Welding Code (AWS D1.1)

The Contractor supplies all Plant and Material, shop fabrication, coatings, and packaging of/for pipe

supports per the Design Erection Arrangement (DEA) drawings, Appendix J. All loose hardware on the

drawing Bill of Materials (BOMs) such as shims, adjustment bolts, etc. is supplied and packaged with the

pipe supports (unless otherwise noted), by the Contractor.

Pipe supports are subject to the Supervisor’s inspection. All documentation is made available to the

Supervisor, by the Contractor. Pipe supports are not packaged for shipment until after the inspection. The

Contractor notifies the Supervisor, at least eight (8) days prior to shipment to permit the Supervisor’s

inspector adequate opportunity for inspection.

The Contractor pre-assembled all supports in shop, to the maximum practical degree, to minimise field

assembly.

The Contractor includes suitable, road-worthy packing and loading onto trucks at the Contractor’s fabrication

facility. The Contractor notes on sling type supports that the minimum radius and the thickness of the rubber

dimensions shown on the drawings are critical and must be adhered to. It is also critical that all support rods

are perpendicular to the support.

The Contractor removes all slag and weld spatter from the welds and adjacent base material.




6.6.5.2 Pipe Supports Shop Fabrication General Notes

Pipe supports are as designated on the DEA drawings and associated documents without substitution of

components or modifications to the design, unless the designated supports are unfeasible in which case the

Contractor seeks the Project Manager permission to alter the design. Alterations to the design are not made

without acceptance.

Structural members and weldment sizes shown are minimum and recommended and are normally as shown.

However, depending upon availability of material, other members of same or greater strength characteristics

may be substituted with the acceptance of the Project Manager. Dimensional compatibility with the overall

design is the responsibility of the Contractor.

Prefabricated field installed pipe supports are packaged and shipped as a unit and identified with

weatherproof pipe support tag number. Drilling is on structural gage. Structural members are SANS Grade

S355JR.

6.6.5.3 Coatings

All plate, angle, pipe posts and structural shapes of the pipe support are hot dip galvanised.

All buyouts/hardware including pipe clamps, U bolts, eye nuts, clevises, hanger rods and Anvil callouts are

galvanized. Threaded components can be zinc plated pending the Project Manager acceptance.

7 List of drawings

7.1 Drawings issued by the Employer

This is the list of drawings, of the existing installation at Tutuka Power Station, issued by the Employer. The

drawings listed below are drawings of the existing installation at Tutuka Power Station. The drawings are

provided for information only and the Contractor is required to confirm the as-built details.

Drawing number Revision Title

Civil and Structural

Existing plant configuration

0.61/3385 7 General layout of gas cleaning plant

0.61/6150 7 Precipitator area – set 1; Precipitator floor slab; General arrangement

0.61/9015 2 Precipitator support

0.61/9014 2 Precipitator support

0.61/9008 1 Precipitator suspension grid

0.61/9007 1 Precipitator suspension grid




0.61/9016 0 Casing of precipitator

0.61/3326 2 Precipitator and main flues to chimney

0.61/3327 2 Precipitator and main flues

0.61/3946 2 Precipitator Set 1; Precipitator bases and ground beams General Arrangement and Concrete details

0.61/3937 2 Precipitator Set 1; Precipitator bases and ground beams Reinforcement Details

0.61/4345 1 Precipitator Set 1; Precipitator Base Type 5; Concrete and reinforcement Details

0.61/8300 1 Precipitator Set 1&5; Precipitator Base Type 7; Concrete and reinforcement Details

0.61/5959 3 Precipitator Set 3&5; Precipitator bases and ground beams General Arrangement and Concrete details

0.61/5960 3 Precipitator Set 3&5; Precipitator bases and ground beams Reinforcement Details



0.61/5968 3 Precipitator Set 2,4&6; Precipitator bases and ground beams General Arrangement and Concrete details

0.61/5969 4 Precipitator Set 2,4&6; Precipitator bases and ground beams Reinforcement Details

0.61/5974 3 Precipitator Set 2,4&6; Precipitator Base Type 5; Concrete and reinforcement Details

0.61/8302 2 Precipitator Set 2,4&6; Precipitator Base Type 7; Concrete and reinforcement Details

Estimated components to be removedThe Contractor removes all Plant and Material as required by the Employers Works Information to produce

the Employers design. If the Contractor is unsure about what Plant and Material to be removed the

Contractor contacts the Project Manager before removing the plant in question. Refer to drawing mark-ups

in Appendix O, for more information.

0.61/8973 2 Longitudinal wall

0.61/12294 3 Precipitator area unit 4,5 & 6; Cable tunnel on grid 42, 52 and 62 – General arrangement and concrete details




0.61/9017 0 Casing precipitator section AA

0.61/9018 2 Casing precipitator section B-B and view

0.61/9012 1 Platforms and stairs on clean gas duct

0.61/9006 1 Footbridge by clean gas duct

0.61/9004 1 Messbühnen am Rohgaskanal (Platforms on raw gas duct)

0.61/8985 3 Raw gas ducting

0.61/8853 0 (Outlet duct)

0.61/9005 4 Protective covering for H.T. rectifier

0.61/8996 2 Crane-rail and platforms with location of rectifier on roof beam

0.61/9000 0 Railing on roof beam

0.61/9011 1 Railing on rain cover

0.61/8981 1 Tread-proof rain-tight cover

0.61/8979 1 Sealing cover

0.61/8980 2 Detail sealing cover

0.61/8986 1 Collecting plate carrier

0.61/9548 0 Support frame gas inlet

0.61/9551 2 Support frame gas outlet

0.61/9549 0

0.61/9550 1 Details for support frame

0.61/9552 2

0.61/8987 0 Gas deflector plates

0.61/8988 0 Current protective tube for roof beam

0.61/8998 0 X-type distribution plate walls

0.61/8983 2 Gas inlet duct

0.61/8984 2 Gas outlet duct

0.61/8982 0 Lower plate spacing and internal catwalks

0.61/9020 0 Gas deletion plates above baffle plates in the hopper




0.61/8975 2 Roof beam

0.61/8976 0 Wind bracing

0.61/8977 0 Middle-wall

0.61/8874 2 Front wall

0.61/8978 0 Details for middle-wall

0.61/9009 1 Details of roof beam

0.61/9557 2 Discharge frame

0.61/9558 1 Tubes for discharge frame

0.61/9559 1 Discharge frame with discharge electrodes

0.61/9560 0 Tubes for discharge frame 7.5m field height 10 strips

0.61/8999 0 X type distribution plate wall details

0.61/3365 0 General layout of gas cleaning plant

0.61/9016 0 Casing of precipitator

Existing hoppers

0.61/8991 3 Dust hoppers

0.61/8992 2 Gas baffle plates in the dust hopper

0.61/8993 0 Inspection door 600 dia for hopper

Design Drawings Issued for TenderThe following drawings are created by the Employer for the fabrication, manufacturing and installation of

the FFP. The Contractor refers to Appendix J, the overall list of drawings and documents created by the

Employer. The Contractor follows the notes made on the drawings.

Where the Contractor requires clarity on any part of the drawings the Contractor refers the comment or

clarification to the Project Manager.

Control and Instrumentation

See Appendix J 0 FFP Loop Connection Drawings

See Appendix J 0 Pulse Air System Loop Connection Drawings

E262392 1 FFP Functional Logic Drawings

0.61/97353 (Sheet 1-33) A Pulse Air System Logic Drawings

0.61/97109 2 FFP Compartment Junction Box Location Diagram




0.61/97110 2 FFP Inlet Flue Gas Path Junction Box Location Diagram

0.61/97111 2 FFP Hopper and Inlet Damper Junction Box Location Diagram

0.61/97112 2 FFP Vent System and Outlet Flue Gas Junction Box Location Diagram

0.61/97335 0 Unit 1-6 FFP Pulse Air System Instrument Location Diagram

0.61/97336 0 Unit 1-6 FFP Pulse Air Cooling System Instrument Location Diagram

0.61/97337 0 Unit 6 FFP Pulse Air System Location Drawing

0.61/97338 0 Unit 5 FFP Pulse Air System Location Drawing

0.61/97166 1 Unit 6 FFP pulse air system control system architecture

0.61/97165 1 Unit 6 FFP control system architecture.

0.61/97179 1 Typical 24 pair analog junction box general arrangement drawing

0.61/97180 1 Typical 24 pair digital junction box general arrangement drawing







0.61/97138 2 Pulse Air Compressor 1 and 2 Cable Block Diagram




0.61/97222 0 Pulse Air Compressor 1 and 2 Motor Cable Block Diagram







0.61/97226 0 FFP&DHP Compressor House HVAC Controller Cable Block Diagram

0.61/97227 0 FFP&DHP Compressor House HVAC Fans Diagram

0.61/97142 1 Pulse Air Cooling System & Cooling Tower Cable Block Diagram

0.61/97143 1 Pulse Air Cooling Tower Cable Block Diagram

0.61/97144 1 Pulse Air & Instrument Air Distribution Cable Block Diagram

0.61/97104 (Sheet 1-4) 2 Casing A LH Compartment Pulsing System Cable Block Diagram

0.61/97105 (Sheet 1-4) 2 Casing A RH Compartment Pulsing System Cable Block Diagram

0.61/97107 (Sheet 1-4) 2 Casing B LH Compartment Pulsing System Cable Block Diagram

0.61/97108 (Sheet 1-4) 2 Casing B RH Compartment Pulsing System Cable Block Diagram

0.61/97101 (Sheet 1-2) 2 FFP Flue Gas Path Cable Block Diagram

0.61/97102 2 Casing A&B Compartment Ventilation System Cable Block Diagram

0.61/97103 (Sheet 1-8) 2 Casing A LH&RH Compartment Cable Block Diagram

0.61/97104 (Sheet 1-4) 2 Casing A LH Compartment Pulsing Cable Block Diagram

0.61/97105 (Sheet 1-4) 2 Casing A RH Compartment Pulsing Cable Block Diagram

0.61/97106 (Sheet 1-8) 2 Casing B LH&RH Compartment Cable Block Diagram

0.61/97107 (Sheet 1-4) 2 Casing B LH Compartment Pulsing Cable Block Diagram

0.61/97108 (Sheet 1-4) 2 Casing B RH Compartment Pulsing Cable Block Diagram

0.61/97191 A Casing A LH Compartment Hopper Heaters Cable Block Diagram

0.61/97192 A Casing A RH Compartment Hopper Heaters Cable Block Diagram

0.61/97193 A Casing B LH Compartment Hopper Heaters Cable Block Diagram




0.61/97194 A Casing B RH Compartment Hopper Heaters Cable Block Diagram




7.2 Drawings Issued by the Contractor

Documents to be submitted in accordance with attached Drawing Submittal Requirements (DSR)

The following information MUST BE SHOWN on each document and drawing submitted:


Eskom

Tutuka Power Station

Unit Number #

Customer Project No. 0635-302B



Appendices

A) Exceptions and Clarifications RegisterB) Vendor Document Submission Schedule (VDSS)C) Site DataD) Control and Instrumentation

1. FFP Instrument list (E263176)2. FFP IO list (E158954)3. Pulse Air System Instrument List (Z0419-000096-235) 4. Pulse (Cleaning) Air System I/O list (Z0419-000097-142 (360-267))5. FFP alarm list (360-1232)6. Pulse Air System Alarm list (0.61/97383)7. Instrument Data Sheets for the cleaning air equipment plant system (Z0149-000131-179).8. Instrument Data Sheets for the FFP system (E277628, E274390, E277540, E277628, E278035,

E277946, E278044, E278079, and E278065).9. Tutuka Instructions to Tender, FFP Unit 4-6 Field Equipment and DCS

E) Fabric Filter CagesF) Jib Crane and HoistsG) Louver DampersH) Poppet DampersI) Tutuka Cleaning/Pulse Air system Valve and Piping ListJ) Drawing ListK) O&M ManualL) Pressure regulating valve and pressure relief valve data pagesM) Compartment Ventilation SystemN) Construction fill in data pagesO) Demolition DrawingsP) Pulse Air HeadersQ) Master Document List (MDL) TemplateR) LOSSS) BRIL BookT) System Requirement Specification (SRS)

1. FFP SRS and Control Philosophy (E211426; rev 2) 2. Pulse Air System Control Philosophy (0.61/97334 or Z0419-000132-225; rev 1)

U) Supplementary informationV) Cleaning Air Equipment

1. Compressor Data Sheet2. Air Dryer Data Sheet3. Pulse Air Receiver Data Sheet4. Instrument Air Receiver Data Sheet5. Pre and Post Filter Data Sheet

W) Electrical Design DocumentsX) Electrical Compliance ScheduleY) Electrical Equipment Technical SchedulesZ) Construction Sequencing

PART C3: SCOPE OF WORK PAGE 205 C3.2 ECC3 CONTRACTOR’S WORKS INFORMATION



C3.2 CONTRACTOR’S WORKS INFORMATION

This section of the Works Information will always be contract specific depending on the nature of the works.

It is most likely to be required for design and construct contracts where the tendering contractor will have

proposed specifications and schedules for items of Plant and Materials and workmanship, which once

accepted by the Employer prior to award of contract now become obligations of the Contractor per core

clause 20.1.

Typical sub headings could be

a) Contractor’s design

b) Plant and Materials specifications and schedules

c) Other

This section could also be compiled as a separate file.

PART C3: SCOPE OF WORK PAGE 206 C3.2 ECC3 CONTRACTOR’S WORKS INFORMATION

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