Addendum - Kenya Electricity Generating Company No... · present 220 KV Overhead Lines connections...

Bid Document

Addendum

Reference Number:

KGN-BDD-03-2019

_Addendum-01

PROCUREMENT OF PLANT DESIGN, SUPPLY AND INSTALLATION OF

OLKARIA I UNITS 1, 2 AND 3 GEOTHERMAL POWER PLANT REHABILITATION

PROJECT

Subject:

General Description

Annex to:

N/A

Code: KGN-OLK01.TD.GEN.BD.002 (rev1.0)

Document: “General Description"

The “CIVIL CONSTRUCTION TECHNICAL SPECIFICATION SECTION A” document

was erroneously duplicated in KGN-OLK01.TD.GEN.BD.002 (rev0.0). The document has

now been revised to KGN-OLK01.TD.GEN.BD.002 (rev1.0) “GENERAL DESCRIPTION”

KGN-OLK01.TD.GEN.BD.002 (rev1.0) supersedes KGN-OLK01.TD.GEN.BD.002

(rev0.0). Disregard KGN-OLK01.TD.GEN.BD.002 (rev0.0) in the Bid Documents.

ACKNOWLEDGEMENT OF ADDENDUM NO.1

We, the undersigned hereby certify that the addendum is an integral part of the Tender

Documents and the alterations set out in the addendum has been incorporated in the Tender

Proposal.

Signed........................................................................................................................................

Bidder........................................................................................................................................

GENERAL DESCRIPTION

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KGN-OLK01.TD.GEN.BD.002

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OLKARIA I UNITS 1, 2 AND 3 GEOTHERMAL

POWER PLANT REHABILITATION PROJECT

GENERAL DESCRIPTION

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

1.0 24/04/2019 Issued for Bid

R. Brogi R. Parri R. Papale

0.0 24/10/2017 Issued for Client approval

R. Brogi R. Parri R. Papale

PROJECT OLKARIA I

EMPLOYER CODE

OWNER PLANT TYPE LOT DOC PROGRESSIVE

REV.

KGN OLK01 TD GEN BD 002 0 1 . 0

CLASSIFICATION

PUBLIC COMPANY CONFIDENTIAL RESTRICTED

Total or partial reproduction and / or utilization of this document are forbidden without prior written authorization of KenGen.

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TABLE OF CONTENTS

1.PROJECT DESCRIPTION ...................................................................................................................... 5

1.1. BACKGROUND ....................................................................................................................................... 5

1.2. HELL'S GATE NATIONAL PARK CONTROL AND ADMINISTRATION .................................................................... 6

1.3. OPERATIONAL AREAS ............................................................................................................................. 6

2.SITE CONDITIONS .............................................................................................................................. 7

2.1. GENERAL ............................................................................................................................................. 7

2.2. SITE ACCESS ......................................................................................................................................... 7

2.3. COMMUNICATIONS ................................................................................................................................ 9

2.4. TOPOGRAPHY ....................................................................................................................................... 9

2.5. METEOROLOGY ..................................................................................................................................... 9 2.5.1. General ............................................................................................................................................. 9 2.5.2. Atmospheric Temperature .............................................................................................................. 10 2.5.3. Rain and Humidity .......................................................................................................................... 10 2.5.4. Wind distribution at Olkaria ........................................................................................................... 12 2.5.5. Air Quality ....................................................................................................................................... 13

2.6. SEISMIC FACTOR ................................................................................................................................. 14

2.7. SOIL AND GEOLOGY ............................................................................................................................. 14

3.HEALTH AND SAFETY ....................................................................................................................... 14

3.1. SAFETY OF PERSONNEL ......................................................................................................................... 14

3.2. WORK AT SITE .................................................................................................................................... 16

3.3. HEALTH AND SAFETY INDUCTION AND TRAINING ....................................................................................... 19

3.4. HAZARD MANAGEMENT ....................................................................................................................... 20

3.5. PROCEDURES FOR WORKING IN OPERATIONAL AREAS................................................................................ 20

3.6. DISPOSAL OF CONSTRUCTION WASTE ..................................................................................................... 21

3.7. REMOVAL AND DISPOSAL OF EXISTING EQUIPMENT................................................................................... 21

3.8. ELECTROMAGNETIC AND ENVIRONMENTAL COMPATIBILITY ......................................................................... 21

3.9. VIBRATIONS ........................................................................................................................................ 22

3.10. SAFETY STANDARDS AND PERSONAL PROTECTION ...................................................................................... 22

3.11. MEDICAL SERVICES AND FIRST AID .......................................................................................................... 22

3.12. EMERGENCY PROCEDURE ...................................................................................................................... 23

3.13. ACCESS AND INSPECTION STRUCTURE ...................................................................................................... 23

3.13.1. Platform, ladders and handrails ...................................................................................................... 23 3.13.2. Civil works ....................................................................................................................................... 24 3.13.3. Manholes ........................................................................................................................................ 25

3.14. SIGNS, SIGNALS AMD BARRICADES .......................................................................................................... 25

3.15. SAFETY ON PUBLIC ROADS ..................................................................................................................... 25

3.16. ILLUMINATION FOR NIGHT SHIFTS ........................................................................................................... 26

3.17. EARTHING, WET WORK AREAS, CONTROL OF ELECTRIC DISCHARGES .............................................................. 26

3.18. FIRE PRECAUTIONS ............................................................................................................................... 26

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3.18.1. Oil tank fire protection ................................................................................................................... 27

3.19. THERMAL INSULATION .......................................................................................................................... 27

4.QUALITY ASSURANCE ...................................................................................................................... 27

4.1. QUALITY ASSURANCE REQUIREMENTS..................................................................................................... 28

4.2. QUALITY ASSURANCE ARRANGEMENTS – QUALITY PLAN ............................................................................ 28

4.3. MONITORING BY THE EMPLOYER/PROJECT MANAGER ............................................................................... 29

4.4. CONTRACTOR QUALITY AUDITS .............................................................................................................. 29

4.5. CONTROL OF SUBCONTRACTORS ............................................................................................................ 30

4.6. INSPECTION AND TESTS ........................................................................................................................ 30

4.7. CONSTRUCTION/INSTALLATION PHASE .................................................................................................... 32

4.8. NON-CONFORMITIES ........................................................................................................................... 33

4.9. RECORDS ........................................................................................................................................... 34

4.10. METHOD STATEMENTS ......................................................................................................................... 34

4.11. QUALITY CONTROL PLAN (QCP) ............................................................................................................ 34

4.12. TESTING AND PERFORMANCE GUARANTEED ............................................................................................. 34

5.PROJECT MANAGEMENT ................................................................................................................ 35

5.1. IMPLEMENTATION SCHEDULE ................................................................................................................. 35 5.1.1. Project Schedule with Proposal ...................................................................................................... 35 5.1.2. Contract Project Schedule .............................................................................................................. 35

5.2. PROGRESS REPORT .............................................................................................................................. 36

5.2.1. Monthly Progress Report ................................................................................................................ 36 5.2.2. Weekly Summary Report ................................................................................................................ 39 5.2.3. Meetings ......................................................................................................................................... 39

5.3. WORKS COORDINATION ........................................................................................................................ 40 5.3.1. Cooperation with the Employer and other Contractors ................................................................. 40 5.3.2. Site Construction Facilities .............................................................................................................. 40

6.DESIGN AND ENGINEERING ............................................................................................................ 41

6.1. BID DOCUMENTS ................................................................................................................................ 41

6.1.1. General ........................................................................................................................................... 41 6.1.2. Documents Submission with Proposal ........................................................................................... 42

6.2. DOCUMENTS AFTER CONTRACT AWARD.................................................................................................. 45 6.2.1. General ........................................................................................................................................... 45

6.3. DOCUMENTS CHARACTERISTICS ............................................................................................................. 48 6.3.1. Size and template ........................................................................................................................... 48 6.3.2. Revision numbering ........................................................................................................................ 49 6.3.3. Tagging system ................................................................................................................................ 50 6.3.4. Symbols and Codes and Standards ................................................................................................. 50 6.3.5. Units and Scale Ratios..................................................................................................................... 50 6.3.6. Quality ............................................................................................................................................ 50 6.3.7. Language and System of Unit of Measurement ............................................................................. 51

6.4. DOCUMENT SUBMISSION SYSTEM .......................................................................................................... 51 6.4.1. Control ............................................................................................................................................ 51

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6.4.2. Identification .................................................................................................................................. 51 6.4.3. Verification ..................................................................................................................................... 52 6.4.4. Engineering Representative ............................................................................................................ 52 6.4.5. Documentation Schedule ............................................................................................................... 52

6.5. DESIGN REVIEW .................................................................................................................................. 53 6.5.1. Design Review Meetings ................................................................................................................. 55 6.5.2. Design Discrepancies ...................................................................................................................... 55

6.6. DOCUMENTS CONTENTS ....................................................................................................................... 56

6.7. REPORTS ............................................................................................................................................ 57

6.7.1. General ........................................................................................................................................... 57

6.8. SCHEDULE FOR DELIVERY OF DOCUMENTS ................................................................................................ 62 6.8.1. Data and Drawings to be Submitted Within One (1) Month .......................................................... 62 6.8.2. Data and Drawings to be Submitted Within Two (2) Months ......................................................... 63 6.8.3. Data and Drawings to be Submitted Within Three (3) Months ...................................................... 64 6.8.4. Data and Drawings to be Submitted Within Four (4) Months ........................................................ 64 6.8.5. Before commencement of manufacture, three (3) sets of: ............................................................ 65

6.9. REVISION OF CONTRACTOR’S DRAWINGS AT SITE ...................................................................................... 67

6.9.1. As Built Drawings ............................................................................................................................ 68

6.10. PROCEDURES ...................................................................................................................................... 68

6.10.1. Erection Procedure ......................................................................................................................... 68 6.10.2. Pre-Commissioning Procedures ...................................................................................................... 68 6.10.3. Commissioning Procedure .............................................................................................................. 69

7.ERECTION, SUPERVISION AND CHECKING OF WORK ON SITE ........................................................ 70

7.1. GENERAL ........................................................................................................................................... 70

7.2. OVERALL TIME SCHEDULE ..................................................................................................................... 71

7.3. SUBCONTRACTED PLANT, MATERIALS AND LABOUR .................................................................................. 71

7.4. ACCESS TO MANUFACTURERS' WORKS .................................................................................................... 71

7.5. TOOLS & EQUIPMENT FOR ERECTION, INSTALLATION & COMMISSIONING ..................................................... 71

7.6. CONTRACTOR’S EMPLOYEES .................................................................................................................. 71

7.7. ALCOHOLIC LIQUOR OR DRUGS .............................................................................................................. 72

8.TRAINING ........................................................................................................................................ 72

8.1. BASIC CRITERIA .................................................................................................................................... 72

8.2. OVERSEAS COURSES ............................................................................................................................. 73 8.2.1. Personnel involved ......................................................................................................................... 73 8.2.2. General subjects ............................................................................................................................. 74 8.2.3. Specific subjects ............................................................................................................................. 74 8.2.4. Costs ............................................................................................................................................... 75

8.3. ON SITE COURSES ................................................................................................................................ 75 8.3.1. Personnel involved ......................................................................................................................... 75 8.3.2. Training program ............................................................................................................................ 75 8.3.3. Costs ............................................................................................................................................... 77

8.4. HV SUBSTATION .................................................................................................................................. 77

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1. PROJECT DESCRIPTION

The aim of this document is to provide a general description and technical specifications for the

rehabilitation of the entire Olkaria I single flash geothermal power plant, including the steamfield and

HV substation (hereinafter called Project).

1.1. BACKGROUND

The Employer, the Kenya Electricity Generating Company Limited (KenGen), generates electricity

from the Olkaria I, II, IV, 1AU power plants, OW914 and OW37/39 Wellhead Stations, at the Greater

Olkaria Geothermal Field, located in the Rift Valley of Kenya within the Hell's Gate National Park and

approximately 120 km north-west of Nairobi.

These power plants generate a total of 605.8 MWe corresponding to:

Olkaria I (Olkaria East Field) produce 45 MWe (Mega-Watt electrical);

Olkaria II (Olkaria North-East Field) produce 105 MWe;

Olkaria IV produce 140 MWe (Olkaria Domes Field);

Olkaria 1AU produce 140 MWe ;

The OW914 Wellhead Station is a small power plant unit that concentrates other small

power plant units (914, 915 and 919) with a total generation capacity of 47.8 MWe.

The OW37/39 Wellhead Station have a total generating capacity of 20 MWe.

These Power Plants provide base load service to the Kenyan power supply network thought the

present 220 KV Overhead Lines connections to Suswa Substation.

The existing Olkaria I Geothermal Power Plant and 132 kV electrical substation, located at the Olkaria

Geothermal field in the Rift Valley, was established in 1980. The installed capacity of the Power Plant

is 45MW, with 3 units of 15 MW each. The electrical substation had, initially, two bays for generator

transformers (one transformer with double secondary, 36/18/18 MVA, to connect generator unit 1

and 2, and another single transformer, 18 MVA, for generator unit 3), and two bays for transmission

lines (to OW 37 substation and to Naivasha/Olkaria IAU substations).

The entire plant has experienced normal wear and tear over the 32 years of operation. Most

equipment of the Project (and substation) is no longer in production (obsolete) and thus the

acquisition of spare parts becomes difficult.

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The Employer has assessed the necessity to upgrade and rehabilitate the existing power plant, steam

field and substation and intends to structure the entire rehabilitation works into one main contract.

Site Location

PROJECT DATA

Project name OLKARIA I Units 1,2 and 3 Geothermal Power Plant

Rehabilitation Project

Employer KENGEN

Target plant start-up /COD TO BE DEFINED

Expected Net Power

(at design condition) not less than 50.7 MWe

SITE DATA

Country Kenya

County Nakuru

Location Greater Olkaria geothermal area

Coordinates 36°18'32.0"East – 0°53'3450"South

Elevation Above Sea Level 1930 m

All activities and works shall be done in agreements with the prescription done by National

Environment Management Authority (NEMA) with the environmental management and co-

ordination act environmental impact assessment license No: NEMA /EIA/PSL/558.

1.2. HELL'S GATE NATIONAL PARK CONTROL AND ADMINISTRATION

The Hell's Gate National Park is controlled and administered by the Kenya Wildlife Service (KWS). All

Works associated with this project shall comply fully with the requirements of KWS where it impacts

upon operation of the National Park.

1.3. OPERATIONAL AREAS

There are Operational Areas near the project site, these being Olkaria I geothermal power plant and

associated steamfield and transmission facilities, OW37, Naivasha/Olk IAU Substation, Transmission

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Lines, and other sites, that could be under the control of the Employer's other contractors. These

Operational Areas are controlled by the Employer, Kenya Power and Lighting Company Ltd (KPLC),

Kenya Wildlife Serviceor other contractors.

It is noted that part of the project works will be undertaken within Operational Areas and, at times,

require connection to, or interfacing with, existing facilities or Portions that have already been

accepted by the Employer. The Contractor shall not cause any unplanned outages or unauthorized

disruption to the operational plants.

The Operational Areas include, but are not limited to the following:

The sites of the Olkaria I Power Plant and Substation, contained within the perimeter

fences, which are under the control of the Employer and KPLC

The wellpads and process areas of the Olkaria I steamfield each within perimeter

fences, which are under control of the Employer and KPLC

The steamfield cross country steam, brine and condensate pipework with associated

access tracks etc within the general areas of the Hell's Gate National Park, which are

under control of the Employer and the KWS

The electrical transmission system within the general area of the Hell's Gate National

Park which is under control of KPLC, the Employer and the KWS

The electrical transmission system within a wayleave traversing private land from the

boundary of Hell's Gate National Park

Any Portions of the Works that have been accepted by the Employer.

2. SITE CONDITIONS

2.1. GENERAL

The technical data included in this specification such as the site location, topography, meteorological

data, soil and geology, tide level data, “as built” documentation, etc., are for the Contractor’s

information only. The Employer assumes no responsibility for accuracy of these technical data. The

Contractor shall perform independent investigations including appropriate soil investigation, route

survey, etc., as necessary to ensure accuracy of these technical data plus any additional investigation

required for the substation and lines design.

2.2. SITE ACCESS

The following information is only for reference and preliminary.

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It is the Bidders’ responsibility to confirm the maximum dimensions and weight to be transported

before submission of their proposal and any other aspect related to transportation, and their

compatibility with the limitations imposed by the existing roads regulations.

Distance between Olkaria I and Nairobi 120 Km:

Figure 1 – Map showing position of Olkaria I geothermal power plant

Access to Site:

Figure 2 – Map showing access to site and communication routes

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Mombasa is the main commercial port in Kenya and meets international standards.

The image above shows the access roads from Mombasa port to the project site. The distance from

the Port to Project Site is approximately 600km

2.3. COMMUNICATIONS

Kenya has a progressive communications network for domestic and international telephone and fax

services. International direct dial is available in most cities and towns. For remote destinations that

do not offer these services, you may have access to mobile services or even radio links for relaying

messages as needed.

2.4. TOPOGRAPHY

A topographical survey conducted for the project site is included in the Appendix C – Topographic

Survey.

2.5. METEOROLOGY

2.5.1. General

Climate - The Project area lies within the Eco-climatic Zone IV that is described as environmentally

fragile and prone to land degradation.

The baseline climate data recorded by the Employer has been evaluated from a model known as

TAPM, and are discussed in succeeding sections below.

Ambient Conditions

Value Units

Dry Bulb Temperature

Range 1.0 – 35.0 °C

Wet Bulb Temperature

Design 18.0 °C

Range 1.0 – 28.5 °C

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Ambient Conditions

Value Units

Nominal Barometric Pressure 0.8 (at 1930 mASL) bara

Rainfall

Average 714 mm/year

Range 387 - 1037 mm/year

Average Relative Humidity

Midday 57 %

Maximum 70 %

Isokeraunic Level Between 60 and 70

days per annum

Ice Nil

Wind

Design Maximum Wind Speed (3 second just at 10m height)

40

In accordance with BS 6399 Part 2: 1997

m/s

Seismic

Horizontal Seismic Coefficient In accordance with UBC 1997, Zone 3

Altitude of Site Above Sea Level 1930 nominal mASL

Table 1- Ambient Conditions and weather data for the Project area

2.5.2. Atmospheric Temperature

The mean minimum monthly temperature in the project area has been recorded to range from 15.9

°C to 17.8 °C with a mean of 16.8 °C the mean monthly maximum temperature range from 24.6 °C to

28.3 °C and the month of July is the coldest, while the hottest month is February.

2.5.3. Rain and Humidity

Rainfall

The monthly distribution of rainfall borrows largely from the national bimodal pattern of rainfall

distribution with long rains in March, April and May while the short rains are received in the months

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of October and November. Generally, the floor of the Rift Valley has lower rainfall than the flanking

highlands. This area experiences a double rain shadow effect from the west and east flanking

escarpments (Mau and Aberdare Range I Kananga respectively).

Rainfall in the project area and its environs is generally low, recording an average of 634 mm annually.

Evaporation exceeds precipitation almost throughout the year. It ranges from approximately 700 mm

per year in areas around the lake to approximately 1,000 mm per year on higher ground, with

variations from year to year.

The baseline daily rainfall is measured at four sites; X2 Campsite, Site, North East Olkaria and Lake

View. Data for the 20-year period between January 1996 and December 2016 has been analyzed to

show the mean monthly rainfall values over the last 20 years in the project area.

The X2, Site, North East Olkaria and Lake View have shown little spatial difference in the mean annual

rainfall. The mean annual rainfalls for the four sites are as follows: 21.17, 20.23, 15.88, and 19.74,

respectively (Environmental and Social Impact Assessment Study Report (ESIA), Source KenGen’s

Olkaria)

Humidity

KenGen Olkaria made the measurements of the relative humidity in between 9AM and 3PM as

indicated in the Table 3-1, below. Based on the data there is modest variation in the relative humidity

across seasons. Normally diurnal variation with higher values are observed in the cooler morning

times; while lower values in the warmer afternoon period at 3PM.

The data provided, contains ambient measured temperature and relative humidity registered at 9

am and 3 pm (9 and 15) and only in working days, not in weekends.

No information is registered for the night-time. Annual proportion of the year under a given wet-bulb

temperature is given in Figure 3-2.

Over half of the total days (57percent) across the year at midday has an ambient wet bulb

temperature equal or below 15°C. 85% of the days has ambient wet bulb at noon equal to or below

16°C and 94% equal to or below 17°C.

Temperature and relative humidity readings for Olkaria:

Period Relative Humidity (%)

Range Average

09.00 hrs 6 - 100 73.5

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Period Relative Humidity (%)

Range Average

15.00 hrs 11 - 91 48.2

Table 3.1 - Relative Humidity reading for Olkaria, Source KenGen

2.5.4. Wind distribution at Olkaria

Figure 3-3, shows wind distribution prepared in roses for the following periods:

December to February

March to May

June to July

September to November

The periods reflect Kenya's main seasons. Automatic wind speed and wind direction data collected

from November 2003 to September 2005 was used to plot the wind roses. The figure indicates that

the general wind pattern at Olkaria is south-east in all seasons except in summer (December-January-

February), when the wind pattern is randomized, characterized by south-easterly and North-

westerly.

Figure 3.2 – Wet-bulb Temperature in the Olkaria area, Source KenGen

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2.5.5. Air Quality

Gas emissions from the existing KenGen Olkaria power stations predominantly consists of carbon

dioxide (95.1 %) and hydrogen sulphide (4.4%). The other gases, which include hydrogen, methane,

nitrogen and oxygen, form 0.5% (wUwt) of the total non-condensable gas fraction. Total geo-gas

forms about 2% of geothermal effluent (Sinclair Knight and partners, 1994).

This is discharged to the atmosphere.

Carbon dioxide and methane are greenhouse gases that have global climate impacts. Apart from

being a greenhouse gas, carbon dioxide combines with moisture in the air to form carbonic acid,

which is a weak acid. Depending on the amount of the acid formed, pH values of rainwater may be

lowered.

Normal precipitation has pH values between 5.6 and 5.65 due to the presence of carbon dioxide in

the atmosphere. Long exposure of high concentration of carbon dioxide has serious impact on human

beings.

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Studies have shown that exposure of various concentrations of carbon dioxide have effects on human

breathing (Kubo et al, 1999).

For more details about air quality see General Technical Requirement Document (code KGN-OLK01-

TDM.GEN.BD.004).

2.6. SEISMIC FACTOR

Olkaria is situated on the East African Rift Valley in a wide zone of active volcanic fault lines that

extend north-south in eastern Africa for more than 3,000 km from Ethiopia in the north to the

Zambezi river in the south.

Horizontal seismic coefficient; in accordance with UBC 1997, zone three (3).

2.7. SOIL AND GEOLOGY

The Olkaria Geothermal Field lies within the Rift Valley of Kenya. The geology is dominated near

surface by rhyolite volcanoes which include deposits of rhyolite and obsidian blocks, bedded ash and

lapilli deposits and weathered massive pumiceous deposits likely formed by pyroclastic flow.

The site has some near surface geothermal activity as can be seen from fumeroles occurring near

hobleys volcano, the area is faulted and folded with steep ridge lines and escarpments. Steep sided,

deep gullies have been eroded through pumice deposits and there are wide areas with low relief

where there has been an accumulation of windblown weathered volcanic ash (loess).

A preliminary geotechnical investigation into the subsoil conditions for the proposed Site at Olkaria I

is included in the Appendix D – Geotechnical Studies.

3. HEALTH AND SAFETY

3.1. SAFETY OF PERSONNEL

Maximum safety, consistent with good erection practice, must be afforded to personnel directly

engaged on this Contract, or who in the normal course of their occupation find it necessary to utilize

temporary works erected by the Contractor or frequent the working area. Reasonable measures shall

be taken to afford adequate protection against material falling from a higher level onto personnel

below.

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It is the objective of the Employer that this project be designed, constructed, started-up,

commissioned and operated without causing injury or death to any personnel (Contractor's or other

parties) or damage to equipment.

The Contractor shall be responsible for the management of health and safety on the construction site

until is handed over to the Employer/Project Manager.

The Contractor shall develop and submit within 30 days of the Commencement Date, a

comprehensive Health and Safety Plan for the execution of the Works for review by the Project

Manager. The Health and Safety Plan shall include the requirements of the Employer's Safety

Guidelines.

A copy of the Employer's Safety Guidelines is included in the Supplementary Information under

Section VI, Chapter SUPPLEMENTARY INFORMATION, Appendix I.

Particular care shall be taken during work at places where parts of the Project are operational or may

be energized, and places where part of the substation is energized. No testing or other work on

existing apparatus or that has been delivered to Site and which is liable to be electrically charged

from any source shall be permitted except under a “Permit to Work” which will be issued for the

purpose by Employer and/or Operating Project Managers. At the completion of the Contract Works

the Employer/Project Manager shall undertake an inspection to ensure the operational safety of the

substations and overhead electricity transmission lines. For this purpose, the Contractor shall jointly

undertake with the Employer/Project Manager and/or KETRACO an inspection of the Contract Works.

The cost of any re-inspection occasioned by non-compliance with the Specification by the Contractor

shall be borne by the Contractor.

Prior to any activities being undertaken outside of the Contractors home office location(s) Health and

Safety plans covering the activities shall be completed and submitted to the Project Manager for

review.

The Contractor shall ensure that all of the Contractor's and Contractor's subcontractors' personnel

comply with the requirements of the Health and Safety Plan.

In addition, the Contractor shall comply with the Kenyan health and safety legislation the health and

safety requirements of the Employer, KPLC/KETRACO and the Kenya Wildlife Service, as applicable,

for all activities and works performed in the Operational Areas.

The Contractor shall convene and chair a monthly health and safety meeting to be attended by the

Employer/Project Manager and lead health and safety personnel from the Contractor and

subcontractors engaged on site. The Contractor shall distribute minutes of these meetings within

three days.

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The Contractor shall participate in inspections and audits conducted by the Employer/Project

Manager and shall respond to corrective actions arising from audit and inspection findings in a timely

manner. The Contractor’s records shall be available for inspection by the Employer/Project Manager.

The Contractor shall appoint a full time dedicated health and safety professional who is appropriately

qualified and has the authority for:

Implementing and maintaining the Contractors Health and Safety Plan;

Ensuring the health and safety systems and processes are implemented, maintained and

complied with by the Contractor and Subcontractors;

Reporting on the health and safety performance of the Contractor and Subcontractors;

Hazard management and mitigation by the Contractor and Subcontractors;

Incident, accident prevention and mitigation;

Incident investigation

Maintaining records

Conducting inspections, identifying corrective actions

Ensuring compliance to the Employer’s health and safety requirements;

Ensuring compliance to the Contractors health and safety plan.

The Contractor’s lead health and safety person shall be point of contact for the

Employer/Project Manager in regard to health and safety matters.

3.2. WORK AT SITE

Before any work commences at the Site, the Contractor shall submit a Health and Safety Plan for its

employees and Subcontractors to the Project Manager for review and approval. This plan shall

incorporate the requirements of any other Governmental Authorities having legal jurisdiction in such

matters.

The Contractor shall carry out all activities in accordance with the submitted health and safety plan.

Copies of the health and safety plan(s) shall be maintained at all locations where activities related to

the Project are being undertaken.

The plan shall include in all the arrangements required to ensure the health and safety of all

Personnel undertaking and affected by the Works.

As a minimum, the Plan shall include the following:

Contract Description

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A description of the works and scope of the plan including a summary of the major

activities and types of work

Details of specialist tasks or procedures required

Areas of the Contract requiring special consideration and procedural requirements, e.g.

presence of public, working adjacent to other contractors.

Contract EHS Structure and System Copy of the Contractor’s health and safety policy

Organization structure

Description of roles and responsibilities of all personnel covered by the plan

Position and name of the Contractor’s senior person who will liaise with the

Employer/Project Manager.

Contract Inductions and Safety Training Outline of induction procedures for all personnel working on the construction site

Details of induction modules or induction course content

Induction records

Register of employee training relevant to the works

Register of personnel holding authorizations, permits, competency certificates, licenses

required for the contract

Dissemination of health and safety information regarding the plan, site hazards and

mitigations to be implemented to the Contractor’s and Subcontractor’s Personnel

EHS Work Practices and Procedures List of company safe work and environmental procedures relevant to the Contract.

Copies of safe work and environmental procedures or instructions

Details of contract operations subject to work permits

Work permit procedures documented

Register of issue of permits

Register of inductions in permit and safe work procedures

Identification of the appropriate equipment to be used including personal protective

equipment

Hot Work Permit procedures

Visual identification of live/in service Plant.

Lockout/isolation procedures for commissioning Plant

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Formal written permit to work system listing lockout points and identifying Plant to be

isolated

Copies of other relevant safe work procedures

Risk Assessment Identification and ranking of existing and potential construction hazards and risks

Procedures for the elimination, isolation or mitigation of hazards and risks

Workplace Environment, Health and Safety Inspections Procedures for monitoring and enforcing the plan including frequency of inspections,

inspection

checklists and close-out of actions arising from inspections

The maintenance of a register of hazards for the Site

Reporting of hazards

Emergency Procedures Emergency procedures including all necessary contact details for emergency and

support personnel/services

First aid procedures including contact details for all first aid staff

Fire prevention and evacuation procedures

Incident Reporting Procedure for incident (near-miss) and accident investigations and reporting including:

− Notification to the Employer/Project Manager within 1 hour of all serious harm

accidents occurring

− Notification to the Employer/Project Manager of all other incidents/accidents within

24 hrs;

− Delivery to the Employer/Project Manager fully documented reports within 48hrs.

− The report shall include the problem, root cause and corrective actions to prevent

recurrence.

Accident register

Health and Safety Performance Monitoring Procedure for review of the plan

Audit procedure

Records to be maintained on site

Register of Project and any inspection records, licenses, etc.

Material safety data sheets for all hazardous goods and chemicals brought onto the Site

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Reporting requirements

Contractor’s on-site health and safety committee

Other Management of visitors

Regular site toolbox meetings shall be held to ensure all Personnel are aware of the current activities

on the Site as they affect health and safety and to maintain safety and safe working practices at the

top of all Personnel’s mind.

Records shall be maintained to include licenses or certificates of competency held by personnel

appropriate to site activities, e.g. vehicle license, crane operation, rigger.

A register of plant and equipment and inspection records shall be kept. The Contractor’s attention is

drawn to the requirements of the Occupational Safety and Health Act 2007 in this regard.

3.3. HEALTH AND SAFETY INDUCTION AND TRAINING

The Contractor shall ensure that all of the Contractor's Personnel shall have participated in a site

induction training program before they commence work at Site. The induction program shall ensure

that the Personnel inducted are fully familiar with the health and safety plan and their responsibilities

under that plan.

No Personnel shall be allowed to work at the Site without prior a complete induction training taking

place. Personnel who have not successfully completed the induction training shall be escorted under

direct and continuous supervision by a person who holds the relevant and current induction and

health and safety training competences.

Health and safety and induction training records shall be maintained for all Personnel working on

Site. These records shall be made available to the Employer and/or Project Manager on request.

The Contractor shall submit the health and safety induction training package to the Employer for

review 14 days prior to the first presentation and thereafter keep the Employer informed of updates

and changes.

The Contractor shall ensure no Personnel perform a task on their own for which they are not trained

or competent, unless that person is working under the direct and continuous supervision of a person

who is trained or competent. The Contractor shall demonstrate to the Employer upon request,

evidence of any Contractor or Subcontractor Personnel training/competencies related to a work task.

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3.4. HAZARD MANAGEMENT

The Contractor shall maintain a comprehensive hazard management system covering all work

activities on and off the Site, in order to systematically identify, assess, and control hazards at the

site that could cause harm or serious harm.

Hazard identification shall take full account of any special requirements concerning the nature,

handling and storage of hazardous materials including fuel oils, gases and chemicals etc., and provide

plant, equipment, buildings, handling procedures, material safety data sheets and other services

accordingly.

Hazards shall be reviewed at least weekly and all updates shall be clearly communicated to all

personnel on the site.

Output from the hazard management system shall be included in the monthly report.

The hazard management system shall be made available to the Employer/Project Manager on

request in a fully auditable format.

3.5. PROCEDURES FOR WORKING IN OPERATIONAL AREAS

All work in Operational Areas shall comply with the Employer's permit to work systems.

All access to Operational Areas will be controlled by the Employer. "Access Permits" will be issued to

the Contractor's employees who require entry to Operational Areas.

Operational Areas that are controlled by KPLC, will also be controlled by "Access Permits" issued by

KPLC in addition to "Access Permits" issued by the Employer. The requirements of KPLC shall be

deemed to be the requirements of the Employer.

The Contractor's employees carrying out work in Operational Areas shall attend a one-day training

course on the Employer's permit to work system. The Contractor shall provide a schedule of

employees that will require training and a timetable for training.

All isolations required for work in Operational Areas will be carried out by the Employer and shall be

checked by the Contractor before the issue of the permit to work.

For all activities in Operational Areas the Contractor shall give a minimum 5 days advance notice.

All activities or work required for the execution of the Works that involves a "risk of trip" for the

existing plant shall be coordinated with the Employer and KPLC, where appropriate, and shall have a

minimum of 21 days advance notice.

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The Contractor shall co-operate with the Employer and KPLC to co-ordinate all works which require

shutdowns with any of the Employers planned shutdowns and to ensure that any other shutdowns

are kept to a minimum.

The Employer reserves the right to cancel any shutdowns for operational reasons. If a shutdown is

cancelled, the Employer will advise the Contractor of the re-scheduled planned shutdown date.

3.6. DISPOSAL OF CONSTRUCTION WASTE

Construction waste shall be disposed of in the following locations:

Scrap metal – The Contractor shall transport the scrap metal to designated areas within

Olkaria as directed by the Employer/Project Manager.

The Contractor shall transport and bury the cementitious slurry wastes to designated

areas within Olkaria as agreed with the Employer/Project Manager.

Hazardous materials shall be disposed of in strict accordance with local regulat ions.

Waste other than scrap metal, cementitious slurries and hazardous materials shall be

disposed to designated areas within Olkaria as directed by the Employer/Project

Manager.

Contractor shall follow guidance from environment disposal of construction waste.

3.7. REMOVAL AND DISPOSAL OF EXISTING EQUIPMENT

Dismantling of all equipment’s and materials, related with the Project, that will not be used after this

project, shall be properly dismantled, maintained and delivered to KENGEN in a place indicated by

KENGEN.

3.8. ELECTROMAGNETIC AND ENVIRONMENTAL COMPATIBILITY

Unless otherwise specified in the Technical Specifications the following prescriptions shall apply to

the protection, control and monitoring equipment.

Electromagnetic Compatibility Immunity requirements shall be in accordance with the latest IEC CENELEC Standard. Thermal Compatibility As for the Thermal Compatibility, the following prescriptions shall apply (IEC 68.2.1 IEC 68.2.2, IEC 68.2.3, IEC 68.2.48, IEC 68.2.56, IEC 68.5.2, etc.). Mechanical Compatibility As for the Mechanical Compatibility the following prescriptions shall apply:

Vibration (IEC 654.3, IEC 255.21.2, etc.): 5 - 8 Hz 3,5 mm d.a. 8 - 150 Hz 1g

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Shock (IEC 68.2.27): ± 15 g peak, 11 ms. half-sine wave

Free Fall (IEC 68.2.32): 1 m

3.9. VIBRATIONS

The Plant shall be designed and constructed to operate within the vibration standards specified

above.

3.10. SAFETY STANDARDS AND PERSONAL PROTECTION

In addition to the requirements specified herein, the Contractor shall comply with applicable safety

requirements of the following documents and/or organizations:

a) Safety regulations in force in the Republic of Kenya; b) US Bureau of Mines; c) USBR - Construction Safety Standards; d) OSHA Occupational Safety and Health Administration;

The Contractor shall provide his personnel, including his subcontractor's personnel, as well the

visitors with appropriate personal safety equipment. The use of such equipment shall be compulsory

and in accordance with the OSHA standards.

3.11. MEDICAL SERVICES AND FIRST AID

First aid services and provisions for medical care shall be made available by the Contractor for all its

staff.

The Contractor shall ensure the availability of medical personnel for advice and consultation on

matters of occupational health.

Provisions shall be made prior to commencement of the project for prompt medical attention in case

of injury.

In the absence of an infirmary, clinic, hospital, that is reasonably accessible in terms of time and

distance to the worksite, which is available for the treatment of injured employees, the Contractor

shall ensure the presence of a person who has a valid certificate in first-aid training or equivalent

training that can be verified by documentary evidence, shall be available at the worksite to render

first aid.

First-aid supplies approved by the consulting physician shall be easily accessible when required. The

first-aid kit shall consist of materials approved by the consulting physician in a weatherproof

container with individual sealed packages for each type of item. The contents of the first-aid kit shall

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be checked by the Contractor before being sent out on each job and at least weekly on each job to

ensure that the expended items are replaced.

The Contractor shall provide proper equipment for prompt transportation of the injured person to a

healthcare facility

Emergency telephone numbers of the Contractor’s first Aiders, healthcare facilitiesand ambulances

shall be conspicuously posted.

Where the eyes or body of any person may be exposed to injurious corrosive materials, suitable

facilities for quick drenching or flushing of the eyes and body shall be provided within the work area

for immediate emergency use.

3.12. EMERGENCY PROCEDURE

The Contractor shall develop, implement and maintain a plan for emergency procedures that will

address all expected emergency situations during construction; such plan shall be properly

coordinated with the emergency plan of the Employer and shall be submitted to the Project Manager

for approval.

The standard of service for medical and life-threatening emergencies shall not be less than that

offered by the Employer. .

The plan shall include proposals for first aid, transporting accident victims to hospital, first aid

education for employees, dealing with fires, etc. The plan shall provide for all types of weather and

working conditions that will be encountered on Site.

The Contractor will be required to demonstrate the effectiveness of the plan by carrying out trials

acceptable to the authorities.

All vehicles and movable equipment shall be marked with numbers and/or letters on both sides for

easy identification, readable at a distance of 100 m. Contractor’s staff shall wear clearly legible

identification.

The Contractor shall monitor forecasted weather conditions and shall take necessary precautionary

measures to ensure the safety of the Works at all times.

3.13. ACCESS AND INSPECTION STRUCTURE

3.13.1. Platform, ladders and handrails

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The Contractor shall supply, erect and test all platforms, galleries, stairways, and ladders necessary

to provide proper means of access for all operation, inspection and overhaul purpose to the various

sections of the Project being supplied under this Contract. All platforms, stairways, galleries and

ladders shall comply with the OSHA standards.

Galleries, platforms and stairways shall be designed considering a minimum load of 750 kg/m2;

platforms shall not deflect more than 1/250 of the free span length when loaded. In case an excess

load is imposed during operation or maintenance, the Contractor shall make due allowance for the

increased loads during the design phase. All necessary supports from the floors, buildings and

foundations shall be supplied under this Contract.

Platforms and galleries shall have a minimum width of 850 mm clear passageway and shall be

enclosed by hand railing on both sides.

All indoor and outdoor metal platforms, stairways, galleries, footrest and handrails shall be in

Peralluman or equivalent material (EN-AW-5000 series alloys). Suitable provisions shall be

considered to prevent corrosion at connection with parts embedded in concrete.

Working platforms for the instrument team are required to access control valves transmitters and all

instruments during maintenance and calibration. Instruments should be housed in suitable cabinets

for their protection and enhance safety in their locations.

Where equipment can be safely reached and operated from the ground level without reaching

“above shoulder height”, platforms are not required. At any rate removable access, catwalks and

platforms shall be provided to allow periodic monitoring and inspection to be done in a safe manner

where permanent platforms are not required. Any platform, bridge, gang way or passage placed at

more than 2 meters above ground level shall have handrails on either side, made of two or more

boards not less than 10 cm wide: the bottom one acting as kickboard against the platform and the

upper one located not lower than 1 m above the platform level.

Ladders shall be in good order, straight and crushproof, shall be secured at the top by means of well-

placed and knotted ropes, or other acceptable means, scissor–type ladders shall not be more than 4-

meter-high, shall have a chain between the leaves and shall be held by an assistant on the ground

when used.

3.13.2. Civil works

The Contractor shall provide permanent access to steam flow Venturies, valves and instrumentation.

Working platforms for the instrument team shall be provided to access control valves transmitters

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and all instruments during maintenance and calibration. Instruments shall be housed in suitable

cabinets for their protection and enhance safety in their locations.

3.13.3. Manholes

Vessels requiring internal inspections by maintenance personnel shall have at least one manhole 600

mm (24”) in diameter, with davit, as required to allow access without problems to the vessel for its

maintenance. The manhole door(s) shall be hinged where appropriate and be capable of being locked

open. Access manhole shall have a platform attachment so an external platform can be mounted.

Platforms shall be supplied by the Contractor. All access structures shall be in accordance with OSHA

requirements. 150 mm (6”) hand-holes shall also be provided for inspection and ventilation where

necessary.

3.14. SIGNS, SIGNALS AMD BARRICADES

Signs and symbols required shall be visible at all times when work is being performed, and shall be

removed or covered promptly when the hazards no longer exist. Signs and symbols include Danger

Signs, Caution Signs, Exit Signs, Safety Instruction Signs, Directional Signs, Traffic Signs and Accident

Prevention Tags. Danger signs shall be used only where an immediate hazard exists. Caution signs

shall be used only to warn against potential hazards or to caution against unsafe practices.

Construction areas shall be posted with legible traffic signs at points of hazard. Accident prevention

tags shall be used as a temporary means of warning employees of an existing hazard, such as

defective tools, equipment, etc. They shall not be used in place of, or as a substitute for, accident

prevention signs.

Barricade means an obstruction to deter the passage of persons or vehicles. Signs are the warnings

of hazard, temporarily or permanently affixed or placed, at locations where hazards exist. Signals are

moving signs, provided by workers, such as flagmen, or by devices, such as flashing lights, to warn of

possible or existing hazards. Tags are temporary signs, usually attached to a piece of equipment or

part of a structure, to warn of existing or immediate hazards.

3.15. SAFETY ON PUBLIC ROADS

The Contractor shall be responsible for the safety along the roads related to the Site, and shall take

all necessary precautions for the protection of the work and the safety of the public on the roads

affected by his activities. Where the work will be carried out at the site of, or close to an existing

road, the Contractor shall maintain the vehicular and pedestrian traffic safe at all times. If the

Contractor’s operations cause traffic hazards, he shall repair or fence or take such other measures

for ensuring safety which are satisfactory to the Project Manager.

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Roads subject to interference by the work shall be kept open or suitable detours shall be provided

and maintained by the Contractor, who shall provide, erect, and maintain all necessary barricades,

suitable and sufficient flashlights, flagmen, danger signals, and signs.

Roads which will be closed to traffic shall be protected by effective barricades on which acceptable

warning and detour signs shall be placed. All barricades and all lights shall be kept burning from

sunset to sunrise.

3.16. ILLUMINATION FOR NIGHT SHIFTS

Protected lighting fixtures will illuminate during the night the working places by illumination level not

less than 30 lux.

Work in proximity of Live System: when the Contractor is working in the vicinity of existing electrical

installations, he shall consider such parts as live and shall therefore take the necessary precautions.

All live areas shall be fenced and warnings declaring “Live area" shall be affixed to each trestle space

not more than 4 m far.

3.17. EARTHING, WET WORK AREAS, CONTROL OF ELECTRIC DISCHARGES

All equipment and appliances which are exposed to lightning shall be earthen electrically and the

effectiveness of such earthing shall be periodically checked by the Contractor's specialized personnel.

No equipment electrically powered by more than 24 Volts shall be operated by personnel standing

in water.

Only air, battery-powered or hydraulic tools shall be permitted in the wet areas.

Where electrical blasting will be used, equipment shall be installed to control possible electric

discharges in the ground due to storms, electrical motors, etc.

As soon as such discharges are noted, electrical blasting operations shall be suspended, unless safety

type detonators are used.

3.18. FIRE PRECAUTIONS

During the months of the dry season, the potential fire hazard in and around all areas of the Site is

extreme. The Contractor shall take all reasonable precautions to prevent fires during construction.

Details of this shall be included in the Safety Plan for review by the Project Manager.

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The Contractor shall organize a firefighting system, for the fighting of any fires, which could break

out on the construction sites, in temporary structures, stores, residential quarters, etc.

3.18.1. Oil tank fire protection

For each tank containing oil and other inflammable liquids, a proper monitoring and fire protection

system shall be provided.

At this regard, refer to doc. Fire Protection System (code: KGN.OLK05.TDM.LT2.BD.005).

3.19. THERMAL INSULATION

Each component which is working at a temperature over 100 °C shall be properly insulated. The

maximum temperature of any element by which O&M staff can be in contact with shall not exceed

55 °C.

4. QUALITY ASSURANCE

To ensure that the supply and services under the Scope of this Contract, whether manufactured or

performed within the Contractor’s works or at his subcontractors’ premises or at Site or at any other

place of work are in accordance with the Specification, with the Regulations and with relevant

authorized standards, the Contractor shall adopt suitable quality assurance programs and procedures

to ensure that all activities are being controlled as necessary.

The quality assurance arrangements shall conform to the relevant requirements of ISO 9001:2008.

The systems and procedures which the Contractor will use to ensure that the Works comply with the

Contract requirements shall be defined in the Contractor’s Quality Plan for the Works.

The Contractor shall operate systems that implement the following:

Hold point - “A stage in material procurement or workmanship process beyond which

work shall not proceed without the documented agreement of designated individuals or

organizations.”

The Employer/Project Manager’s written agreement is required to authorize work to

progress beyond the hold points indicated in reviewed quality plans.

Notification point – “A stage in material procurement or workmanship process for which

advance notice of the activity is required to facilitate witness.”

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If the Employer/Project Manager does not respond to documented notifications within the specified

period in the the agreed procedures, the Contractor will deem the notification as approved and may

proceed with the work.

4.1. QUALITY ASSURANCE REQUIREMENTS

The Contractor and subcontractors, shall, for all phases of work to be performed under the Contract,

establish and implement quality assurance arrangements which, as a minimum, meet the

requirements of ISO 9001:2015, “Quality management systems: Requirements”.

The Contractor shall ensure that all work carried out under the Contract is performed by suitably

qualified and skilled personnel and that good quality materials, which meet relevant international

standard specifications, where such exist, are used.

4.2. QUALITY ASSURANCE ARRANGEMENTS – QUALITY PLAN

The Contractor shall submit a comprehensive contract specific Quality Plan for review and comment,

within two weeks of award of Contract.

The Quality Plan shall identify as a minimum:

the Contractor’s organization and responsibilities of key management including quality

assurance personnel;

the duties and responsibilities assigned to staff ensuring quality of work for the

Contract;

the prime project documents, specifications, codes of practice, standards;

the correspondence and reporting interfaces, and liaison between the Employer/Project

Manager and the Contractor;

the procedures the Contractor intends to use to manage and control the Contract,

including:

o the duties and responsibilities assigned to staff ensuring quality of work for the

Contract;

o hold and notification points;

o submission of engineering documents required by the Specification;

o the inspection of materials and components on receipt;

o reference to the Contractor’s work procedures appropriate to each activity;

o inspection during fabrication/construction;

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o final inspection and test.

It is recommended that separate Quality Plans be submitted for the design/manufacture and

construction/installation phases.

The Contractor shall review, amend and re-submit quality plans as necessary during the Contract.

All tests must be witnessed and approved by the Employer.

4.3. MONITORING BY THE EMPLOYER/PROJECT MANAGER

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

implementation of the Contractor’s quality assurance arrangements.

The Contractor’s compliance with equipment, documentation, drawing, delivery, construction,

installation and commissioning schedules shall be monitored by the Employer/Project Manager.

Monitoring may be by means of a program of formal audits and/or surveillance of activities at the

work locations. Where deficiencies requiring corrective actions are identified the Contractor shall

implement an agreed corrective action program. The Employer/Project Manager shall be afforded

unrestricted access at all reasonable times to review the implementation of such corrective actions.

For site work the Employer/Project Manager may monitor all aspects of the Contractor’s daily work

including that of subcontractors and assess the achievement of milestones as detailed by schedule

deliverables.

The Employer/Project Manager reserves the right to monitor the subcontractors and the Contractor

shall ensure that all subcontracts include, and subcontractors are aware of, this requirement.

4.4. CONTRACTOR QUALITY AUDITS

The Contractor shall carry out a formal program of project quality audits. These shall include audits

of the design, manufacture, assembly, erection, installation, test and commissioning functions of the

Contractor’s organization and those of its subcontractors and suppliers. The Employer/Project

Manager reserves the right to accompany the Contractor on such audits.

The Contractor shall formulate a 6-month project specific audit program, covering 6-month periods,

which shall be submitted to the Employer/Project Manager for review within 4 weeks of the Effective

Date of the Contract and thereafter every 6 months. Any revision to the audit program shall be

forwarded to the Employer/Project Manager.

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4.5. CONTROL OF SUBCONTRACTORS

The Contractor shall be responsible for specifying the quality assurance requirements applicable to

subcontractors and suppliers, for reviewing the implementation of subcontractors’ quality assurance

arrangements and for ensuring compliance with the requirements.

The Contractor shall ensure that all appropriate technical information is provided to subcontractors

and suppliers. The Contractor shall, for the supply of items, plant or equipment (including those

subcontracted), arrange for suitable protection for the product at all stages including delivery and

installation at the site.

The Contractor shall submit, for information, a detailed program defining the basis of control to be

applied to each subcontract or supply order.

4.6. INSPECTION AND TESTS

Inspection and test plans shall be prepared for all major items of equipment/plant, defining the

quality control and inspection activities to be performed to ensure that the manufacture and

completion of the Project complies with the specified requirements.

Inspection and test plans shall be submitted for review.

The Contractor shall submit for review, within 30 days of the Contract Award, a schedule defining the

plant/equipment/systems/services that are to be subcontracted, identifying all items for which

inspection and test plans will be submitted.

The Contractor shall review all inspection and test plans and associated control documents, of any

subcontractors and suppliers, to ensure their adequacy prior to submission.

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

in the country of manufacture.

Inspection and test plans may be of any form to suit the Contractor’s system, but shall as a minimum:

Indicate each inspection and test point and its relative location in the production cycle

including incoming goods, packing and site inspections.

Indicate where subcontract services will be employed (e.g. subcontractor NDT or heat

treatment).

Identify the characteristics to be inspected, examined, and tested at each point and

specify procedures, acceptance criteria to be used and the applicable verifying

document.

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Indicate mandatory hold points established by the Employer/Project Manager that

require verification of selected characteristics of an item of process before this work can

proceed.

Define or refer to sampling plans if proposed and where they will be used.

Where applicable, specify where lots or batches will be used.

The Contractor shall include in all orders to subcontractors, a note advising that all materials and

equipment may be subject to inspection by the Employer/Project Manager as determined by the

inspection and test plan. Copies of such purchase orders shall be forwarded to the Employer/Project

Manager.

In order to verify compliance with engineering, procurement, manufacturing requirements and

programmes, the Employer/Project Manager shall have access, at all times, to all places where

materials or equipment are being prepared or manufactured, including the works of the Contractor’s

subcontractors or supplies of raw materials.

The Contractor shall advise the Employer/Project Manager of the readiness of inspection at least 4

weeks prior to a nominated inspection/surveillance witness or hold point. Work shall not proceed

beyond a hold point without the written agreement of the Employer/Project Manager or his

nominated representative.

Inspection of the plant/equipment may be made by the Employer/Project Manager and could include

the following activities:

Periodic monitoring to confirm the effectiveness of, and the Contractor’s compliance

with, the established quality plan, system procedures and inspection and test plan.

Witnessing of inspections and tests and/or verification of inspection records to be

carried out at the Employer/Project Manager’s discretion covering:

o compliance of raw material with specified requirements

o compliance of manufactured parts, assemblies and final items with

specifications, drawings, standards and good engineering practice

o witnessing of inspection and tests

o packing for shipment including check for completeness, handling requirements,

and case markings and identification.

Raw materials, components, shop assemblies, and the installation thereof, shall be subject to

inspection and test by the Employer/Project Manager as required by the Specification and to the

extent practicable at all times and places, during the period of manufacture.

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The Contractor shall keep the Employer/Project Manager informed in advance of the time of starting

and of the progress of the work in its various stages so that arrangements can be made for inspection

and for test. The Contractor shall also provide, without additional charge, all reasonable facilities and

assistance for the safety and convenience of the Employer/Project Manager in the performance of

his duties. All of the required tests shall be made at the Contractor’s expense, including the cost of

all samples used.

The Contractor shall not offer, unless otherwise agreed, any item of equipment or system for

inspection to the Employer/Project Manager until all planned inspections and tests to date have been

completed to the satisfaction of the Contractor.

The Employer/Project Manager shall endeavor to schedule the performance of inspection and tests

so as to avoid undue risk of delaying the work. In the event of postponement, by the Contractor, of

tests previously scheduled, or the necessity to make additional test due to unsatisfactory results of

the original tests, or other reasons attributable to the Contractor, the Contractor shall bear all costs

for new tests and the costs incurred by the Employer/Project Manager or his nominated

representative in re-inspecting the non-conforming item or its replacement.

The inspection and tests by the Employer/Project Manager of any equipment/component or lots

thereof does not relieve the Contractor of any responsibility whatever regarding defects or other

failures which may be found before the end of the defects liability period.

The Contractor shall provide a quality release certificate confirming compliance with the Contract

requirements and a data book, comprising the inspection, test, qualification and material records

required by the pertaining specifications.

No material shall be shipped to the Site or put to work until all tests, analysis and inspections have

been made and certified copies of reports of test and analysis or Contractor’s certificates have been

accepted and released by the Employer/Project Manager or by a waiver in writing.

4.7. CONSTRUCTION/INSTALLATION PHASE

Within 30 days of mobilization of works, inspection and test plan(s), similar in form and content to

that described in the ‘Inspection and Tests’ part of this specification above, shall be submitted

defining relevant inspection and test points for all stages of construction/erection, installation and

commissioning. The inspection and test plans shall identify activities for which method statements

shall be prepared.

Method statements shall be submitted to the Employer/Project Manager for review.

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Programs of site construction works shall be submitted to the Employer/Project Manager, giving

notification of forthcoming test/inspections on a weekly basis.

4.8. NON-CONFORMITIES

All items or services not in accordance with the Contract technical specification, or deviating from a

previously reviewed document, shall be considered non-conforming.

All such items shall be clearly identified and isolated where practical, and reported to the

Employer/Project Manager via a non-conformance report. Information to be provided with non-

conformance notifications shall include:

identification of the item(s);

reference to relevant specification/drawings, including applicable revisions;

reference to the application inspection and test plan stage;

description of the non-conformance, with sketch where appropriate;

method by which the non-conformance was detected;

cause;

proposed corrective action, with technical justification, where necessary;

for significant non-conformances, proposed action to prevent recurrence;

applicable procedures.

The Employer/Project Manager shall have complete authority to accept or reject any equipment or

part thereof considered not to be in accordance with the specified requirements.

Approval of any concession applications is the prerogative of the Employer/Project Manager, and

approval of a particular case shall not set a precedent.

Any non-conformances identified by the Employer/Project Manager shall be notified by issue of the

Employer/Project Manager’s non-conformance report to the Contractor. Notification of re-

inspection shall not be made until the completed non-conformance report, together with any

applicable concession applications have been accepted by the Employer/Project Manager.

Acceptance or rejection of the equipment and/or components will be made as promptly as

practicable following any inspection or test involvement by the Employer/Project Manager. However,

failure to inspect and accept or reject equipment and/or components shall neither relieve the

Contractor from responsibility for such items, which may not be in accordance with the specified

requirements, nor impose liability for them on the Employer/Project Manager.

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4.9. RECORDS

Records packages to be delivered shall be agreed with the Employer/Project Manager prior to

setting-to-work of each phase, i.e. design, manufacture, construction, installation and

commissioning.

4.10. METHOD STATEMENTS

Prior to commencing work, the Contractor shall submit method statements setting out full details of

his methods of working. This is a hold point.

4.11. QUALITY CONTROL PLAN (QCP)

The Bidder shall submit the QCP in the bid. It must be agreed with the Project Manager.

The QCP shall contain the minimum tests required and deemed necessary for a correct control of the

materials and equipment supplied. The QCP proposed by the Bidder shall contain information about

the technical specifications, tests foreseen and the appropriate reference standards.

For each test, the Project Manager will indicate whether requires that his representatives should be

present (by notifying or mandatory convocation) or if a certification will be sufficient for the purpose.

Any notice of execution of tests (requiring or not the Project Manager and/or Employer personnel)

shall be transmitted with 10 days of advance as specified in the Order.

The Contractor shall carry out the tests required in the QCP at his own expenses, except for the

expenses concerning Employer’s representatives.

At the end of the construction the Quality Book must contain a detailed description of all the tests

carried out at Contractor’s (or subcontractors') factory. It will be submitted to the Project Manager

for approval, in order to declare the “end of manufacturing in the workshop” phase completed and

activate the payment of the relative quote.

4.12. TESTING AND PERFORMANCE GUARANTEED

About testing to be performed refer to doc. KGN-OLK01.TD.GEN.BD.006, Testing and Commissioning

Specification.

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5. PROJECT MANAGEMENT

5.1. IMPLEMENTATION SCHEDULE

5.1.1. Project Schedule with Proposal

The Bidder shall provide a detailed Project Schedule with his proposal.

The Proposed Schedule shall be a network form with critical path including following information:

Date for Commencement of Work

Dates for start and completion of design engineering for all disciplines.

Dates for the placing of orders for material, receipt of material, fabrication and

manufacture, factory testing.

Date for topographical survey and geotechnical investigation.

Dates showing start and completion of site construction of each activity.

Dates for delivery of major equipment.

Dates for all interfaces.

5.1.2. Contract Project Schedule

The Contractor shall submit to the Project Manager his project implementation schedule using Gantt

charts or equivalent format, and showing the critical path. Such schedule shall be an update of the

schedule proposed in the Bid, but including modifications agreed during contract discussions.

The Project Implementation Schedule (PIS) shall cover the complete period of project (design,

fabrication, erection, pre-commissioning, commissioning, acceptance tests and Operational

Acceptance).

At the request of the Project Manager, additional updates shall be issued by the Contractor when

this is considered necessary by the Project Manager.

The schedule and all related updates shall be submitted by the Contractor to the Project Manager

both in hardcopy and in electronic format.

Specialized schedules shall be prepared and submitted by the Contractor to facilitate project

monitoring and communication between the Project Manager and the Contractor.

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The reviewed schedule shall be submitted to the Employer as part of the Contract Document to be

signed and will become the Contract Schedule.

The Contractor shall prepare and submit within 30 days of the Commencement Date, for the

Employer/Project Manager review and approval, a detailed critical path schedule for the Works in

both Critical Path Method and Gantt chart format. The schedule shall be prepared in Primavera

computer software. Both hard (printed) and soft (native format) copies shall be submitted. A

milestone listing alone will not be acceptable.

The Contractor shall co-operate with the Employer/Project Manager in ensuring that the schedule

incorporates the effects of other work being undertaken on the Works, or the wider project, by the

Employer/Project Manager or other contractors. The schedule shall incorporate milestone dates for

each interface identified in the interface schedule.

The schedule shall be constructed to allow electronic extraction of summaries in such a way as to

enable roll up to higher levels for management reporting purposes. In particular, the schedule shall

have separate sections covering manufacture, procurement and shipping, civil/structural

construction works, erection and commissioning.

The schedule shall clearly identify the critical path for the Work and interface milestones. It shall

contain information on resource loadings, both for labor and equipment.

The schedule shall incorporate sub-schedules as required covering work by sub-contractors.

Detailed programs for all Work to be executed during the first twenty-four (24) weeks of the Contract

shall be submitted 30 days after the Effective Date of the Contract.

These programs, which shall embrace design, procurement, manufacture, testing, shipping and

erection on Site shall be based on the Contract Schedule and shall be used as target programs possibly

subject to revision.

The detailed programs shall be submitted to the Employer at twelve (12) week intervals, updated to

reflect the changes that have accrued in the previous twelve (12) weeks and to show the detailed

program of Work for the next twenty-four (24) weeks.

5.2. PROGRESS REPORT

5.2.1. Monthly Progress Report

The Contractor shall prepare and submit to the Employer within 7 days from the end of every month,

a written Monthly Progress Report summarizing the progress of the various sections of the works

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both in the factory and at Site. Such progress reports shall indicate accurately the status of different

activities covering design, major procurement, manufacture, factory tests, shipping, erection, testing

and commissioning and shall be related to key dates identified. The report shall also include data on

labor strength and equipment employed at the Site.

The contractor shall also submit daily progress reports. The daily report submitted shall be reviewed

and certified by the Employer.

The Monthly Report shall include the Contract Schedule indicating progress and individual

component progress made in the month.

Such schedules shall show cumulative progress towards scheduled completion (expressed as a

percentage) of all items shown in the Contract Schedule.

The report shall indicate the degree of criticality in each section of the work together with the

slippage or impending slippage on any key event and shall be directly related to the Contract Schedule

and Supporting detailed network for sections of work.

Two (2) hard copies and a soft copy of the Monthly Progress Report shall be submitted to the

Employer in English in a format approved by the Employer.

The monthly progress report shall include executive summary containing to, but not limited, as

follows:

An approved the schedule

additional written comments (also to be provided in hard and soft format) describing

the status of the Works,

the percentage completion of all activities against planned completion,

the achievements of the previous month,

activities to be undertaken during the following two months, including resource

requirements,

any impacts being experienced on the critical path and milestone dates,

actions being undertaken to maintain or recover the critical path and milestone dates,

actions required of the Employer/Project Manager

Safety report, including:

− Summary of Contractor and Sub-Contractors on site and numbers of respective

personnel;

− Safety statistics including accidents, incidents and near misses;

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− Commentary on significant incidents;

Comment on inductions;

− Comment on updates to Contractor’s Health and Safety Plan;

− Contractor’s safety activities;

− Details of safety meetings and toolbox talks;

− Details of site audits and inspections undertaken;

− Planning for future safety activities.

Environmental compliance

any other items of significance or interest to the Project,

colored photographs showing the progress of work on site.

Plant & equipment procurement including:

− specification number and revision, title,

− vendor,

− date purchase order placed,

− manufacturing status,

− inspection schedule,

− planned shipping date,

− actual shipped date,

− planned delivery date,

− actual delivery date and

− current physical location.

The daily works progress report shall include:

Work progress records

Labor returns

Plant and Equipment returns

Weather records

the achievements of the day,

activities to be undertaken the following day, including resource requirements,

Measurements and Test carried out

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Extraordinary events

Approvals obtained or rejected or denied

Records of accidents and near misses

Meetings and visitors to site

The Contractor shall submit their proposed progress report structure to the Employer/Project

Manager within 21 days of the Commencement Date for agreement.

5.2.2. Weekly Summary Report

The Contractor shall prepare and submit to e Employer two (2) hard copies and a soft copy of a weekly

summary report covering all the site activities. This report shall include projected Work activities for

at least 14 days after those being reported upon.

In addition, this report shall include a weekly site labor return giving expatriate and local labor and

each Subcontractor’s labor broken down into trades.

Constructional Plant, machinery, offices and materials and include Site and weather conditions which

may affect the progress of the Works. This weekly summary report shall also include percent

complete against planned information by discipline and bulk commodities installation information:

cubic meters of concrete, linear meters of cable, tonnes of structural steel, cable terminations, etc.

The weekly report shall include also a four (4) weeks look ahead schedule and detailed works

completed in previous two (2) weeks.

5.2.3. Meetings

Progress review meetings shall be held at least once per month. The timing shall permit informed

discussion of the most recent monthly progress report and shall normally be 7 days following the

submission of the monthly progress report. The venue of such meetings shall normally be at site, but

may be changed by mutual agreement between the Employer/Project Manager and the Contractor.

Additional meetings shall be held as required by the Employer/Project Manager. In particular, more

frequent meetings shall be held on Site to coordinate Site activities.

Minutes of all meetings will be prepared by the Employer/Project Manager. These minutes will

document the main points of discussion and any agreements reached, rather than providing a

verbatim record of the discussions. The draft minutes prepared by the Employer/Project Manager

shall be forwarded to the Contractor for review, and shall be completed and returned with comments

to the Employer/Project Manager within 5 days of receipt.

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The minutes thus prepared by the Employer/Project Manager and incorporating the Contractor’s

comments, shall be the official record of the meeting.

5.3. WORKS COORDINATION

5.3.1. Cooperation with the Employer and other Contractors

The Contractor shall cooperate with the Employer and the Project Manager and other Contractors

and coordinate its activities with the activities of the Employer's other Contractors under the Project

Manager's direction to ensure the proper interfacing of the equipment and the work.

5.3.2. Site Construction Facilities

The Contractor shall provide and use construction equipment capable of producing the quality and

quantity of Works required by the Contract and within the time specified in the Contract.

Before starting with execution of any portion of work at the Site, the Contractor shall provide at the

Project Manager's request relevant information and drawings of construction equipment and

facilities.

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6. DESIGN AND ENGINEERING

6.1. BID DOCUMENTS

6.1.1. General

Employer’s Drawings included under this Section VI, Chapter DRAWINGS, are a reference guide for

the Bidder. The Bidder shall submit its own drawings as a part of the bid documentation.

The Bidder shall fill in all the forms, as required in the Bidding Documents, and shall submit the

drawings and information specified for the various items in the relevant chapters of these Employer’s

Requirements.

The Bidder shall provide all the information needed to clarify his understanding of the present

Employer’s Requirements, making reference to similar Plants already built in the past and including

their description and technical characteristics. Particular attention shall be paid to the selection of

materials for the various parts and components.

The Bidder shall provide information to clearly show that the Project is designed in order to meet the

prescriptions of these Employer’s Requirements.

In particular, the Bidder shall provide the layout and elevation views and/or sections of the Project,

revised according to the equipment being offered, including technical literature showing the

suitability of equipment for its intended application.

The Bidder shall submit sufficient details of the equipment including overall size, materials and

weights in order to enable the general arrangement of the Project and the determination of the

process of erection and mounting.

Drawing issued with this Specification known as Bid drawings show the arrangements of Projects and

Systems required by the Employer and are intended to be a reference guide.

The Bidder is requested to bid the Works in accordance with the Employer’s arrangements (where

present).

If the arrangements of Project proposed by Bidder are different from the Employer’s arrangements,

such differences shall be fully explained and justified in the proposal.

The Bidder shall arrange the equipment, panels, lines and other system components in such a way to

give ample maintenance space.

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The overall plans and diagrams shown in the Bid Drawings are preliminary only. Bidder shall make all

complete optimized design to meet the requirement of standards, codes applicable and the

specifications to associated system.

6.1.2. Documents Submission with Proposal

Bidder shall submit, with his proposal, all data, information and drawings requested in Specifications,

as minimum.

A minimum expected reference list of documents is the following:

Site Organization

Method Statement covering the whole of the activities

Mobilization Schedule

Engineering, Procurement & Construction Schedule

Project Details

Quality Assurance/Quality Control Plan.

Functional Guarantees

HES Plan in compliance with the prescriptions of this Volume

Proposed Personnel

Resume of Proposed Personnel

Proposed Subcontractors for Major Items of Project and Installation Services.

List of spare parts for commissioning

Two years supply of mandatory spare parts and consumables

The prescriptions contained in the previous listed documentation shall apply to the supply. Any

deviation from the requirement has to be pointed out in the offer, and it will be evaluated if the

proposed modification is acceptable or not.

6.1.2.1. General Arrangements

Layout with elevations and sections showing the Project arrangement, principal dimensions, parts to

be assembled on Site, and shall also clearly indicate the laydown areas and major component removal

routes. The general Project arrangement drawing shall include sufficient plan and elevation views to

show the arrangement of all equipment both horizontally and vertically in relation to each other.

General arrangement of all significant items of the works to be supplied, including cross

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section drawings and details, for:

o Turbine, stationary and rotating parts;

o Generator and exciter; - Switchyard;

o Condenser, ejectors and inter/after condensers, liquid ring vacuum pumps and

separators;

o Cooling tower;

o Seal pit and Pumps for circulating water;

o Heat exchangers of the cooling water system;

o Steam demister;

o Overhead travelling crane.

o Olkaria I Substation;

o Olkaria I Substation Modification and Extension;

o All Interfaces

o Well pad Separators

o Well pad Silencers

o Well pad atmospheric ponds.

General arrangement of the steamfield.

General arrangement of all control panels, switchboards, HV equipment, transformers,

etc.

Proposed foundation concept (showing extent of piling), arrangement and detail

drawings for all major Project equipment and buildings structures supplied under this

Contract.

Layout of all buildings with equipment arrangement.

Layout and arrangement showing power cable, control cable, trenches and duct routes.

Layout and arrangement showing OHL and towers.

Layout and arrangement showing all buildings.

6.1.2.2. Description of All Project Equipment and Systems

Descriptions, brochures, control philosophy data sheets, characteristic operating curves for all the

main equipment above (including head, power, NPSH vs flow for the Hot Water Pumps and the

Cooling Water Pumps).

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6.1.2.3. Diagrams

Power Plant preliminary P&ID (at least the ones that have been included in Bid

Documents- Part II);

Steamfield preliminary P&ID (at least the ones that have been included in Bid

Documents- Part II)

Heat and Mass Balance diagrams showing the guaranteed specific mass consumption at

100% MCR and, for information, at 80% MRC and 100% with air wet bulb temperatures

at 19 °C, 21 °C, 24 °C, 27 °C; Heat and mass balance shall be made also at design wet

bulb temperature and different load conditions (50 and 75% of MCR)

Heat and Mass Balance diagrams of the steamfield

Mollier diagram showing the turbine steam expansion lines at the above loads;

Diagrams and correction curves:

Correction curves of MCR showing the effect of departures from the rated design

parameters on the measured output

Curves showing the mutual effect of design parameters, needed in order to clarify the

design and performances of the Plant

-Cooling tower performance curve (KaV/L vs L/G),

-Generator capability diagram,

Typical loop diagrams for analog and digital signals;

Block and circuit diagram showing the recommended trip scheme;

HV Electrical single line diagram of Olkaria I Substation;

HV Electrical single line diagram of Olkaria I Substation, including protection diagrams.

HV Electrical single line diagram of Olkaria I Substation, including safety interlock

diagrams.

Control Diagram of Olkaria I Substation.

Protections Diagram of Olkaria I Substation.

430/240 Vac Electrical single line diagram of Olkaria I Substation, including protection

and safety interlock diagrams.

110 Vdc Electrical single line diagram of Olkaria I Substation, including protection and

safety interlock diagrams.

Interface Diagrams and Detailed Lists organized by systems and entities.

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6.1.2.4. Technical Specifications

Technical specifications covering type and design of all principal systems, equipment and

components.

6.1.2.5. Technical Data Sheets

The Schedule of Technical Information indicated under this Section VI, shall be completely fulfilled

by the Bidder, for each plant and equipment.

6.1.2.6. Quality Assurance and Quality Control Data

Quality Plan for the Works, including quality assurance and quality control data.

6.1.2.7. Health and Safety

Health and Safety Plan for the Works, including induction and training program.

6.1.2.8. Proposed Construction Schedule

Proposed Schedule with all phases detailed as required and with Interfaces activities.

6.1.2.9. Statements of Design Intent for Structure, Civil and Building Works

Statements of design intent for civil works which define the extent and purpose of works to be

designed, including description of the technical solutions and materials considered.

6.2. DOCUMENTS AFTER CONTRACT AWARD

6.2.1. General

Following the award of the Contract, the Contractor shall prepare and provide to the Employer for

review and approval all documents (including but not limited to drawings, work method statements,

job safety analysis, reports, specifications, schedules and calculations) necessary to describe the

Works and for proper supervision by the Employer of the work involved and to provide a detailed

and comprehensive record of all aspect of the Contract Works.

The Contractor shall conduct a detailed inspection with KenGen of all the existing facilities before

starting the detailed design of the project. KenGen will facilitate the detailed inspection by the

Contractor by shutting down the Plant for a maximum period of forty five (45) days. The 45 days

shutdown shall not be counted as part of the project implementation time. The Contractor shall

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familiarize with all facilities for re-use purposes that should be incorporate in the design and later

works. For any defects omitted by detailed inspection, the contractor shall be responsible. KenGen

shall be responsible for any unforeseeable defects derived from the existing facilities.

The works methods statements shall be submitted for earthworks, piling, concrete works, erection

works, pipe support works, access platform works, drainage works, road works, pipe erection and

welding works. The extent of the submissions shall be sufficiently comprehensive to establish that all

Plant, Materials and procedures forming part of the Works comply with the requirements of the

Contract.

The Contractor shall provide to the Employer/Project Manager a schedule of documentation to be

provided, indicating the date by which each document shall be submitted both initial draft and final

within 30 days of the Commencement Date. Documents are to be submitted in a logical sequence

such that each submission shall be capable of being reviewed without having to wait for subsequent

submittals. The Project Manager shall have the right to require the Contractor to submit such

additional information as shall be reasonably required. The Contractor is responsible that documents

are submitted in sufficient time to permit re-work if required.

The Contractor shall submit to the Employer/Project Manager hard (printed) copies and soft copies

of documentation in accordance with the agreed schedule of documentation described above. All

printed documentation provided shall be of good quality, clear, legible and able to be used by the

Employer/Project Manager to produce further copies by photocopying. All soft copies shall be in a

common industry standard format (such as Microsoft Office, Adobe etc.) to be agreed with the

Employer/Project Manager. As a minimum, text documents shall be in Microsoft Word, spreadsheets

shall be in Microsoft Excel, data bases shall be in Microsoft Access, drawings shall be in AutoCad 2010

or earlier and schedules shall be in Primavera or mutually agreed equivalent.

Where the Contractor is required to specify the performance requirements for Project including, but

not limited to turbine, generators, cooling towers, cooling water pumps, control system, HV

equipment, instrumentation, transformers and power converters the data and requirements shall be

set out in the format generally attached to the relevant specification or standard. Should the relevant

standard not include specimen data sheets, the requirements shall be set out on a data sheet in a

form generally recognized as appropriate in the industry.

The Contractor shall begin to submit for Project Manager's approval, before manufacture is started,

all calculations and detailed working drawings of the Project.

Manufacture shall not begin until the corresponding documents have been approved. The drawing

details shall include the net weights of all items.

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As soon as manufacture has started, before the equipment is ready for shipment, the Contractor shall

deliver to the Project Manager the relevant drawings.

The Contractor shall submit to the Project Manager the appropriate calculations (calculation reports)

showing the determination of the principal sizes of the Project as well. The calculations shall include

consumption of the users (steam, air, water, heat, gases, electric energy etc., as applicable), the

forces on the equipment determining the capacity of the hooks and of the motors, the stresses on

pressure vessels and main pipes etc. Details of foundation loads and forces to be supported by the

concrete structure and the structural calculation reports for foundations, piles, reinforced concrete

structures and steel structures shall also be provided.

In case the calculation results are obtained by means of calculation codes, the calculation report shall

contain the following information as minimum requirement:

Type of analysis (e.g. static, dynamic, linear, non-linear, etc.);

Origin and characteristics of the calculation codes adopted;

Ranges of applicability of the adopted codes;

Validation of calculation codes;

Input values and constraints;

Information concerning the computations performed;

Evaluation on results reliability.

The erection drawings shall show the foundation details and the position of all rods, pockets, bolt-

holes and the provision for grouting, etc. They shall include details of parts to be built into and loads

to be transferred to the civil works, description of erection methods and details of connections if any

to any other equipment.

The Contractor shall submit for Project Manager’s approval all drawings for embedded parts in due

time to permit approval by the Project Manager prior to the dates set out in the program.

The Contractor shall prepare comprehensive Method Statements for all major activities and submit

these to the Project Manager for approval prior to the commencement of the relevant activity. The

method statements will include, but not be limited to, working methods, construction Project

utilization, temporary works, construction sequence, and security and safety arrangements.

When the Contractor prepares his Contractual Construction Program, he shall make allowance for

and indicate the dates expected for submittal and approval of drawings by the Project Manager.

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The Contractor will provide routine procedures for commissioning and performance and guarantee

tests, suitable for the best use of his equipment. The Contractor shall also provide a specimen form

containing procedure and calculations for converting the “as run” output to rated conditions (MCR).

When the manufacture is approaching the end, the Contractor shall submit the final procedures for

the performances and guarantee tests and the Operation and Maintenance Manuals.

During the commissioning period and the following performance and guarantee tests, the Contractor

shall record all the actions taken, the readings and calculations in a log book to be handed over to

the Project Manager.

All drawings and documents prepared by the Contractor or his Subcontractors shall bear an approved

contract reference and title and title block and Employer’s reference drawing number.

All documentation whether letters or drawings shall show the project title and number.

The Employer will not normally require to receive copies of detailed manufacturing drawings but the

Contractor shall make this available to the Employer if so requested.

All drawings shall be to scale and fully detailed and dimensioned. The material of which each part is

to be constructed shall be indicated. Each drawing shall be clearly stamped to indicate the applicable

status e.g. “For preliminary”, “For Information”, “For Review”, “For Approval”, “For Construction”,

and “As Built”.

6.3. DOCUMENTS CHARACTERISTICS

6.3.1. Size and template

With the exception of drawing and certain other forms such as certificates, all other documents shall

be size A4. The maximum sheet size for drawings shall be size A1.

Documents sized A0 are not acceptable.

Except in instances where the original drawing is size A4, drawings for inclusion in technical manuals

should be size A3, double folded to size A4. If drawings of size larger than A3 are required to, drawings

shall be folded with title visible and bounded along with the left-hand side.

All documents greater than size A3 must be capable of reduction to size A3 with no loss of symbol,

lettering legibility, etc. Such drawings shall also have a minimum left-hand margin of 25 mm at size

A3 to ensure that no information is obscured by binding.

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The Contractor shall provide two (2) sets of electronically versions of all documentation and

drawings.

The drawings shall have a template in the lower right-hand corner showing:

Name of Employer,

Name of the Employer’s Consultant,

Name of the Contractor,

Project title,

Contract number and title,

Title of drawing (location, item and detail),

Scale,

Date of drawing,

Revision identification,

Date of issue,

Record of the previous revisions with relevant issuance dates and description of

changes made,

Serial number in accordance with drawing classification system.

6.3.2. Revision numbering

During their development cycle, all documents shall carry a revision number and date. After the initial

issue of a document as Revision A, all revisions will be assigned the next higher alphabetic or numeric

character as noted below:

A, B, C, etc. Internal distribution or Issued For Information (IFI) to Project Manager or others as Preliminary information 0 Used to obtain client review or approval -- Issued For Review (IFR) or Issued For

Approval (IFA) 1, 2, 3, etc. Approved for Design (AFD) or Approved for Construction (AFC) Issued for Design (IFD) or Issued for Construction (IFC)

The Revision Table shall consist of the following:

Revision number/letter

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Reason for revision

Drawn

Checked

Approved

Date

All revisions to drawings shall be identified by a 10 mm wide revision triangle containing the revision

number and a revision cloud around changed areas. Each re-issued drawing shall have the changes

noted and described in the revision section of the drawing title block. Revision clouds and triangles

will be shown for the current revision only.

6.3.3. Tagging system

All Project and equipment identification shall correspond to numbering defined in a Tagging System

Specification approved by the Employer.

6.3.4. Symbols and Codes and Standards

Documents shall comply with relevant international standards for Construction Drawing Practice

Graphical Symbols. This includes but is not limited to the following:

ISO 128-1982 Technical Drawings - General Principal of Presentation

ISO/R 129-1959 Engineering Drawings – Dimensions

ISO 1000 The International System of Units (SI) and its Applications

6.3.5. Units and Scale Ratios

All drawings shall be supplied in SI metric units using one of the following scales 1:1, 1:2, 1:5, 1:10,

1:25, 1:50, 1:100, 1:200, 1:500, 1:1,000, or 2,500. Third angle projection shall be used throughout.

All drawings shall be provided with a scale bar.

6.3.6. Quality

Paper used for documentation shall be suitable for long term storage (minimum 80 g/m2). All

drawings shall comply with the relevant standards.

All drawings shall be stored in electronic format in CAD format.

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6.3.7. Language and System of Unit of Measurement

The English language shall be used in all written communications between Employer, the

Employer/Project Manager and the Contractor with respect to the services to be rendered and with

respect to all documents and drawings procured or prepared by the Contractor pertaining to the

work.

Whenever anything is required under the terms of the Contract to be marked, printed or engraved,

the English language shall be used except where otherwise provided in the Specification.

The design features of all equipment, all quantities and values which are required to be stated in the

Schedules of Technical Information and all dimensions on drawings whether prepared by the

Contractor or not shall be stated in the International System of Units (SI).

6.4. DOCUMENT SUBMISSION SYSTEM

6.4.1. Control

The Contractor shall, for all work to be performed under the Contract, establish and maintain a

comprehensive computer-based document control system ensuring that, at all phases of the work

the identification, revision, status and location of documentation is determined. The Contractor’s

system shall also provide for all Subcontractors’ and Bidders’ documents.

At the end of each reporting period the Contractor shall provide to the Employer a complete hard

and electronic record and electronic copies of all drawings, submissions, documents and

correspondence delivered in both hard and electronic form during that reporting period.

6.4.2. Identification

The Contractor shall develop and maintain an identification system for all project documentation for

permanent inclusion in the Works which shall enable the Contractor to control the documentation in

the live phase of the project and enable the employer to fully, efficiently and to the standards

required by the contract, operate and the Project by providing ready access to the system. The

Contractor shall therefore develop a method to identify documents to their specific process system

and any interfaces appertaining thereto. This philosophy shall be maintained in the assembly of the

required Engineering, Project Operations, Maintenance, Spares and Quality Records.

The Contractor’s adopted computer based system shall be transferable to standard personal

computers and transferred to the Employer at the completion of the Works as part of the

documentation.

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Provision shall be made by the Contractor to provide full training in the use of the identification

system by the Project Operator in readiness for hand over the system.

6.4.3. Verification

When submitting all documentation including any prepared by a Subcontractor, the Contractor shall

verify that he has fully examined such drawings and that they comply with the requirements of the

Contract.

6.4.4. Engineering Representative

If the Contractor intends to divide or subcontract any part of the work, it shall ensure that the design

is fully coordinated between all the parties involved prior to submission of relevant drawings and

documents for review and approval. For this purpose, he shall designate an individual or group of

individuals charged with the execution of this coordination work. The Contractor shall provide an

organization chart clearly indicating the interfaces involved and identifying the individual to whom

the Employer can refer as the “single point of contact” for this design coordination effort. The

Contractor shall have their engineering representative in their office in Nairobi and/or the Project

Site available to the Employer for technical discussions during the entire duration of the Project. The

subject engineering representatives shall cover mechanical, electrical, civil/structural and

instrumentation and control engineering disciplines and shall have full knowledge of the design

requirements with full authority to resolve any discrepancies and to act to implement all design

resolutions and Employer’s directives. The time required to consult the Contractor’s head office shall

be minimized.

6.4.5. Documentation Schedule

The Contractor shall provide a detailed schedule of documents to be produced during the Contract

in accordance with the Document Schedule for submission to the Employer. The schedule shall

indicate, by generic type, those supplied for approval (specifications, procedures, etc.) and those for

information. Typical documentation to be provided shall include, but not be limited to the following:

Copy of topographical and soil investigation results and interpretation

List of design codes to be followed

Detail of all loadings, both actual and assumed, incorporated into the designs. Where an

interpretation of codes of practice is necessary, e.g. for wind and seismic loading, the

assessment and conclusion shall be clearly stated.

Material data to include strength of materials and source of manufacture of all

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structural elements (include details with Tender)

Calculations for all structural, civil and building work

Specification of equipment

Manufacturer’s test certificates

Layout drawings

Interfaces drawings

Single-line and Multi-line drawings

Protection drawings

Equipment sizing calculation

Selectivity Studies and Protections Settings

Control diagram

Communications diagram

Others as specified in the individual specification

The schedule of documentation shall also indicate to the Employer those specific design, safety and

related elements required for third party verification and, where possible, the proposed third party.

The detailed drawing list shall comprise all drawings and documents the Contractor will produce on

which the Employer will decide which drawings or documents will have to be submitted for approval,

information or any other purpose. The list shall be reviewed and up dated from time to time in

progress of the design and construction.

6.5. DESIGN REVIEW

Within 30 days after the Commencement Date, the Contractor shall submit to the Employer/Project

Manager for review a design plan which shall include inspection plan, pertinent drawings and

document schedules and submissions. The Employer/Project Manager may, within 30 days of receipt

of the plan, and in consultation with the Contractor, select one or more submissions as a mandatory

“HOLD” point before the item concerned can be released for further design, procurement, fabrication

or construction.

Where a “HOLD” point has been identified by the Employer/Project Manager in accordance with this

section of the Employer/Project Manager’s Requirements, the Contractor shall not proceed beyond

the “HOLD” point without an instruction from the Employer/Project Manager advising that the

“HOLD” has been released. Where the item for submission is on the critical path for the completion

of the Works, the Contractor shall so advise the Employer/Project Manager of the status of the

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submission. The Contractor shall take account, in his programming of the work, for the time required

for the review and release of drawings and documentation, whether the documents are critical or

not.

The Employer/Project Manager reserves the right to carry out independent review and verification

of any aspect of the Contractor’s design. Where such review identifies non-compliance with the

Contract requirements, the Contractor shall make modifications to the design to ensure compliance.

Such modifications shall not be considered to be grounds for any extension of time or variation.

Documents submitted for review shall have been processed in accordance with the Contractor’s

Quality Assurance procedures and shall be certified by the Contractor as having been fully examined

by him and in compliance with the requirements of the Contract. The Contractor shall allow a period

of 28 days for The Employer/Project Manager to review and comment on each submittal of

documents.

The Employer/Project Manager will advise the Contractor of the status of all documents submitted

for review as one of the following:

“Rejected” - Non-compliant with the Contract. The Employer/Project Manager’s

Representative will identify the non-compliance. The document shall be re-submitted.

Work shall not proceed until the rejected document is revised addressing the non-

compliance and re-submitted and reviewed by the Employer/Project Manager.

“Non-Compliant as Noted” - The Employer/Project Manager will identify the non-

compliance. The document shall be re-submitted as soon as possible with the noted

amendments. Work may, however, proceed at the Contractor’s risk pending formal

release, based on the noted amendments.

“Released” - Work may proceed on the basis of a reviewed document.

“Noted for Information” – The document has been noted for information, but formal

review was deemed unnecessary by the Project Manager.

When the document is approved the word “Approved” shall be stamped on it.

After approval of drawings by the Project Manager, the Contractor shall supply to the Project

Manager one (1) set of updated copies immediately after each revision. No major revisions shall be

made after approval of a drawing without resubmitting the drawing for formal approval of the said

revision.

Any manufacture, assembly or installation of Works or portions thereof prior to the approval of

pertinent drawings shall be at the Contractor's risk.

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It shall be understood that approval of the drawings will not exonerate the Contractor from any

responsibility in connection with the correct execution of the Works.

All drawings/documents submitted for approval or sent to the Project Manager for any other reasons

shall be sent by registered mail.

As soon as erection of the Project is complete, the Contractor shall supply to the Project Manager

high quality printouts of all drawings and diagrams. These copies shall have been updated where

necessary to represent the as-built work as erected, and shall be marked with an "As-Built" stamp of

reasonable size.

All cost for preparation, submittal, modifications and re-submittal of all documents and information

required under this Contract shall be deemed to be included in the Contract Price.

6.5.1. Design Review Meetings

When the design has achieved sufficient progress, periodic Design Review meetings will be held

between the Contractor and the Employer and the Project Manager at the Contractors Design Office.

In order to shorten the time required for Design Review and to allow the earliest possible time for

site mobilization, it is expected that the Employer and the Project Manager will meet the Contractor’s

design staff in the Employer’s home office (or on site) on several occasions to expedite drawing/

design approval. The Bidder shall therefore allow in its bid all costs associated these meetings.

6.5.2. Design Discrepancies

The Contractor shall be responsible for the correction of incomplete design data, omissions and

design discrepancies which become apparent during construction. The Contractor shall provide the

Employer with a proposed recommendation for correcting a design error within three (3) calendar

days after notification by the Employer. The Employer will notify the Contractor of any detected non-

compliance with the foregoing requirements.

The Contractor shall take immediate corrective action after receipt of such notice. Such notice, when

delivered to the Contractor at the worksite, shall be deemed sufficient for the purpose of notification.

If the Contractor fails or refuses to comply promptly, the Employer may issue an order stopping all

part of the work until satisfactory corrective action has been taken. No part of the time lost due to

such stop orders shall be made the subject of claim for extension of time or for excess costs or

damages by the Contractor.

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6.6. DOCUMENTS CONTENTS

General Requirements

A scale bar shall be included to permit use following sizereduction.

All drawings which relate to another will have a reference to that drawing located in a Table placed

in a prominent position on the drawing.

All cross sections which are taken from another drawing will be cross-referenced to the parent

drawing.

Similarly, all section indications will indicate the drawing number the section appears on.

Standard sizes shall be metric A0, A1, A2, A3 and A4. Drawings shall be prepared in such a way that

photo-reduction to size A3 shall result in a legible and useable drawing. Particular attention shall be

paid in this respect to selection of fonts. When drawings larger than A3 are submitted, an A3 print

shall also be submitted.

Each drawing submitted shall clearly indicate the applicable status, e.g. Preliminary, for Information,

for Review, for Tender, for Construction, As Built.

General Assembly Drawings

Outline of all components with overall dimensions including any space requirements for

maintenance or installation access.

Locations of connection points for various services and other equipment should be

dimensioned and labelled.

Where applicable, the drawing shall show where and how the equipment is fitted or

connected to other plant equipment without infringing the space provided for other

civil, structural, mechanical and electrical equipment such foundations, steel supports,

piping ducts, cables, conduit, clear ways, valves, etc.

Cross Section Drawings

Parts and construction details shown fully dimensional and where necessary a Parts

Table showing materials and description of components shall be included in the same

drawing.

As-built drawings shall be supplied to the Employer/Project Manager in hard and soft

format. The soft format shall be suitable for importing into Microsoft Access based

database application software.

Support Load Drawings

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Forces and movement shall be shown in the local axis of the drawing. All loads shall be

divided into dead, live, weather related loads occasional and operating loads.

Loads shall have the following definitions:

− – Dead Load Self weight of static components.

− – Live Load Weight of moving components.

− – Occasional Load Seismic, wind, etc.

− – Operating Load Thermal centrifugal, etc. Loads which are created during normal

operation.

Schematic Diagrams

Mechanical, electrical and control schematics, process flow diagrams, and piping and

instrumentation diagrams which extend beyond a single sheet shall be logically arranged such that

sheets can be pasted together to provide a continuous diagram. All lines extending beyond one sheet

shall be clearly marked to identify the continuation line. Where other drawings are also required for

cross reference in reading the drawing, the reference and relationship of such drawings shall be

clearly stated on the drawings.

6.7. REPORTS

6.7.1. General

Each design report submitted shall include, but shall not be limited to, the following:

General description of system, philosophy, principles, methodology, etc., relevant to the

subject matter of the report.

List of codes and standards used in the report.

A list of all assumptions implicit or explicit in the report.

A summary of the results of any calculations, plus a full set of calculations where

appropriate, including when required for statutory approvals (e.g. pressure vessels).

A set of A3 drawings associated with the report, bound into the report, with sets of full

size drawings supplied separately.

All other information relevant to the subject matter of the report.

An appropriate QA certification for the report, bound into the front of the report after

the title page.

Geotechnical Report

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The detailed geotechnical report shall include at least the following information:

Records of all geological investigations and soil tests undertaken. Each test and

investigation shall be included as a separate appendix to the report. A brief description

shall be provided of each test, including the test equipment, along with a reference to

the applicable code or standard to which the work was undertaken.

Plans showing the location of the sites and locations of all soil sample/tests on and off

the site (i.e. test pits, bore holes, penetrometer tests etc.).

General geological description of region and its formation.

Description of soil types encountered on and off the site, referenced to borehole/test

pit logs.

Schedule of physical and derived engineering properties of soil types.

Statement on recent calibration or certification of test equipment used.

Summary of expected loads (short or long term) from the main structures/buildings.

Statement on suitability of soil types to support the expected loads.

Recommended foundation types for the different structures on the site.

Susceptibility of soils to liquefaction under earthquake or vibration from rotating

machinery

Recommended design methods and formulas for determining allowable soil pressures for shallow

and deep foundations (provide reference).

Recommended allowable soil pressures and appropriate safety factors or load factors to

be used for different load cases/combinations. Provide both Limit State stresses and

elastic design (allowable stress) stresses.

Assessment of probable settlement of foundations under short and long-term

conditions (with due reference to vibration or dynamic loads from rotating machinery).

Stability of natural, cut and filled slopes with recommended set back clearances for

buildings, roads and similar features. Identify areas with unacceptable or marginal

stability and specified remedial options.

Recommended compaction standard for fill, (optimum density, water content and

permitted variation) including field methods.

Recommended design parameters for retaining walls.

Recommended design parameters for roads and other pavements.

Civil and Structural Design Report

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The report shall address at least the following issues:

Adoption of solutions to issues raised in the Geotechnical Report

Expected settlements

Drainage systems

Pavement and external ground works

Foundation systems

Floor systems

Building frame, seismic and wind load resistivity systems

Seismic Design Report

A specialist seismic engineer shall, prior to manufacture and construction, certify in writing that he

has personally reviewed the calculations/drawings/test results and concepts adopted for the detailed

design of the Project (e.g. buildings, structures, and the seismic coefficients and holding down

arrangements for mechanical equipment and electrical equipment), and has found them to satisfy

the requirements of this seismic specification.

At construction documentation stage, the Contractor shall provide for the Project Manager’s

Representative review a Seismic Design Report which shall describe in detail for all aspects of the

Project the following:

The seismic design concepts, assumptions and seismic load derivations used in

satisfying the performance requirements specified. This shall include detailed

descriptions of all the matters listed below:

A description of the intended seismic design codes and associated material design

codes. This shall include a statement as to the design method (e.g. Ultimate Strength

Design, Working Stress design) and load combinations.

A description of interpretation of the specified hazard spectra for use with the

nominated seismic codes, including any adjustments for ductility, damping and risk.

categorization of the principal items of structure, plant, equipment and control systems

which identifies which items are critical to the safe shutdown of the Power Plant in the

event of the Design Earthquake (DE) occurring.

A description of the likely damage to the Power Plant if the DE occurs.

The hierarchy of failure expected with increasing levels of seismic shaking above the

Operating Basis earthquake (OBE) level up to the DE and also for earthquake shaking in

excess of DE.

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For brittle components, factors of safety assumed in methods of design.

Intended methods of demonstration of seismic adequacy of complex and/or proprietary

items.

The report shall also report on the geotechnical investigations in so far as they define the subsoil

category and any potential for liquefaction. Special analytical and/or physical modelling studies

undertaken to confirm that the design concepts chosen will meet the requirements.

Operation and Maintenance Manual and Commissioning Log Book

The Contractor shall provide comprehensive and coordinated manuals to enable the operators to

fully understand the aspect of design, operation and maintenance of the Power Plant. The

Commissioning and Performance Log Book shall report all the activities carried out in such a period.

The Operation and Maintenance Manuals shall be arranged in three sections:

Sectional arrangement and plot plan, main side view, PFD’s, P&ID’s, electrical

diagrams;

Procedures for operation and maintenance and related documentation;

Lists of components (equipment, pipes, valves, instrumentation, spare parts),

Manufacturer’s Data Sheets;

DCS inputs/outputs list (with set points, signal type, alarm set points, logic states, and

trip points.);

Instruments Interconnection Wiring Diagram (IWD);

Inspection and Test reports, which should state much information as possible, including

but not limited to test points, procedure used and signal injected.

Each section shall be divided into as many volumes as practical for convenient handling and

reference, in order to accommodate all plant systems, as they appear in the list of contents of these

Employer’s Requirements and in the same order in each section; for instance:

Mechanical Equipment

Liquid-Steam Separators

Atmospheric Silencers

Steam Receiving System

Turbine and auxiliaries

Condensing and gas extraction system

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Circulating water system

Auxiliary cooling system –cooling and closed-circuit systems

Cooling tower

Electrical Equipment

Generator and auxiliaries

Ancillary electrical equipment

Transformers

Well pad electric panel

Control System

Control and instrumentation

DCS (distributed control system)

Control function

Electric, pneumatic and hydraulic instrumentation

Metering system - Protection relays - Synchronizing and AVR system

PLC equipment

Main machine interface

Chronological events recorder

Communication system

Services

Sludge removal system

Domestic water supply system

Condensate collection and reinjection system

Water treatment system

Firefighting and monitoring plant

Gas monitoring system

Compressed air system

Power house overhead crane

Security

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Telephone and communications

The Contractor shall submit to the Project Manager final installation data for all Project equipment.

The final installation data shall be confirmed and signed off by Contractor’s QA/QC, the

Consultant/Project Manager’s site staff.

Comprehensive cross-references shall be included amongst the different list of contents, in order to

facilitate tracing of documents.

The format of pages shall be A4 and A3 folded to A4.

Manuals from different manufacturers shall have the same arrangement.

Manuals shall reflect the “As Built” documents. Any change that might occur after the run tests,

following the punch list, shall be included.

First submittal of the Operation and Maintenance Manuals shall be delivered in:

Four (4) printed copies;

Three (3) CDs;

Final version of the Operation and Maintenance Manuals and the Commissioning and Performances

logbook shall be delivered in:

Eight (8) printed copies;

Three (3) CDs

6.8. SCHEDULE FOR DELIVERY OF DOCUMENTS

The Contractor shall provide the following information to Project Manager for approval, in agreement

with the following time schedule, unless otherwise specified in the relevant chapters of these

Employer’s Requirements.

If not otherwise specified, deadlines start from the Effective Date.

Documents shall be always provided by the Contractor both in hardcopy and softcopy (editable

native format files are required for text documents and for drawings); where not specified, one

copy/set of document means one paper print and one CD Rom (or DVD).

6.8.1. Data and Drawings to be Submitted Within One (1) Month

Within one (1) month of the Contract Effective Date, the Contractor shall submit the following, but

not limited.

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General description and technical specification of all major equipment item.

Contractor’s organogram.

Overall layout and general arrangement of all major plant (including switchgear, control

and relay panels) giving foundation requirements showing locations, dimensions, loads

and details of cable trenches required.

Contract program.

One (1) copy in English of all codes and standards approved for use in this Contract.

Inspection Test Plan (ITP) and quality test procedures at factory for all equipment

supplied under this Contract.

Equipment and system identification numbers using standardized KKS (Kraftwerks

Kennzeichen System/Identification system for Power Plant) Number System.

Comprehensive Health and Safety Plan for the execution of the Works.

Contractor’s Quality Plan for the Works.

Detailed Interface List

List of drawings and technical documents to be submitted for approval and for

information,

Time schedule of first submittal, time expected for approval and re-submittal,

Report on Construction Facilities including layouts, drawings and description,

WPS (welding procedure specifications) for all welds.

6.8.2. Data and Drawings to be Submitted Within Two (2) Months

Within two (2) months of the date of the Contract Effectivity, the Contractor shall submit the

following, but not limited.

Complete equipment list of all substations and lines items and equipment to be

supplied together with the name of the manufacturer or Subcontractor, country of

origin, and FOB delivery date.

Control system architecture, functional logic diagrams for control, alarm and sequence

interlocks.

Drawing list summarizing all existing and proposed drawings of principal items intended

for submission to the Employer by the Contractor together with the submission dates.

Schedule of all AC and DC loads.

Detailed time schedule, containing design and manufacturing, delivery, erection and

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commissioning,

Complete equipment list of all plant items and equipment to be supplied together with

the name of the Manufacturer or Sub-Contractor, country or origin, and FOB delivery

date.

Schedule for material and equipment workshop tests.

Procedures for pre-commissioning,

Training program,

Final outline dimensions of the civil works,

Detailed general arrangement and construction drawings for all major plant items

Foundation layout, with static and dynamic loads,

Method Statements for Civil Works (prior to the commencement of the relevant

activity),

6.8.3. Data and Drawings to be Submitted Within Three (3) Months

Within three (3) months of the date of the Contract Effectivity the Contactor shall submit the

following, but not limited.

All Lines layout drawings.

Cables and Conduits routing.

Cable diagrams and diagrams of connections for all plant items, junction boxes and

control panels and itemized cable schedule.

Electrical Schematic diagrams including power, control, indication, protection and

alarms.

Detailed general arrangement and construction drawings for all major items.

Schedules of consumable items, lubricants and chemicals.

6.8.4. Data and Drawings to be Submitted Within Four (4) Months

Within four (4) months of the date of the Contract Effectivity the Contactor shall submit the following,

but not limited.

Full manufacturer’s data sheet on every type of device, equipment, or module which

the Contractor proposed to utilize in the protection and control system including

computer hardware and software.

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Functional group control diagrams.

Evidence of submission of plans for approval, where necessary, to local authorities.

Heat balance diagrams for of 100% load conditions,

Process Flow Diagrams and Process Instrument Diagrams, including single line loop

diagram for all control valves, for all systems,

Circuit and wiring diagrams for all circuits,

Pipes, cables and air ducts routes,

Isometric drawings for Power Plant piping,

AC and DC short circuit calculations,

Load flow calculation,

Stress analysis for main components,

Any other calculations as required in the Employer’s Requirements,

Voltage drop sizing,

Final Power Plant layout, elevations and 3D views,

DC system sizing,

Logic schematic diagrams,

Earthing and lightning calculations,

Photometric design,

I/O lists,

Instruments lists,

Pipe and valves list,

Cable list,

Schedule of paintings,

Evidence of submission of plans for approval, where necessary, to local authorities.

Electrical schematic diagrams, including power, control, protection and alarms.

Electrical measure and protection diagrams

Electrical Protection Relay Setting

6.8.5. Before commencement of manufacture, three (3) sets of:

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Detailed manufacturing drawings with all important dimensions, final assembly

drawings, governing and control schemes, tubing and piping schemes, cabling and

wiring diagrams and block and circuit diagrams intended to aid understanding and to

provide full information about the principles of operation,

Performance and stress calculations as the Project Manager may require,

Critical speed calculations for turbine, generator and for the coupled turbine-generator,

Stability and regulation characteristics calculations,

Protection relays setting calculations and co-ordination of the protective devices,

List of sub-orders,

Detailed information (type, make, etc.) on products used for priming and painting of all

components.

6.8.5.1. During manufacture, three (3) printed sets of:

Progress reports at monthly intervals,

Notices of tests and shop inspections,

Inspection reports,

Certificates of tests and inspections.

6.8.5.2. Not later than one calendar month before shipment, three (3) sets of:

Packing lists of each consignment,

Instructions for loading, unloading, handling, and precautions for the storage on Site.

6.8.5.3. Not later than three calendar months before commencement of erection, three (3) copies of:

Installation drawings, detailed circuit diagrams and protection study,

All erection procedures and instructions,

All approved drawings,

List indicating the special lifting devices and special tools,

Detailed erection program,

Inspection program indicating main activities of inspection, including a site test

schedule,

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Preliminary operation and maintenance manuals.

6.8.5.4. Not later than one calendar month before commencement of erection, three (3) copies of:

All policies of insurance related to the site work.

6.8.5.5. During erection, three (3) copies of:

Progress reports at monthly intervals,

Work log book reporting on the day to day activities.

6.8.5.6. Not later than two calendar months before commencement of Pre-commissioning, three (3) copies of:

Final program and procedures for pre-commissioning for each section, including

updated correction curves, if needed,

Operation and Maintenance Manuals.

6.8.5.7. Not later than one calendar month before commencement of Commissioning of each unit, three (3) copies of:

Final instructions, conditions and procedure of commissioning and testing.

6.8.5.8. Before Operational Acceptance of the Facilities:

"As Built Drawings", six (6) sets of paper prints (A3 size)

"As Built Drawings", six (6) sets of CD Rom or DVD

Pre-commissioning, Commissioning and performances log book, six (6) copies,

Final "Operation and Maintenance Manual", updated with data added during

commissioning and testing, six (6) paper print copies,

Final "Operation and Maintenance Manuals", updated with data added during

commissioning and testing, six (6) sets of CD Rom or DVD.

6.9. REVISION OF CONTRACTOR’S DRAWINGS AT SITE

During the erection and commissioning period it may be necessary on the approval of the Employer

to make revisions to already approved construction drawings. In such case the Contractor shall

provide to the Employer at Site without delay two (2) marked-up prints detailing any revision made.

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Normal revisions of these drawings shall then be made and issued to the Employer as described

earlier.

6.9.1. As Built Drawings

During execution of the Works, the Contractor shall update and maintain on file current mark-ups of

all drawings and data sheets to agree with actual work undertaken. The Contractor shall prepare as

built of the documentation to fully describe the entire Permanent Works. As-Builts shall be submitted

to the Employer/Project Manager for record purposes prior to operational acceptance.

As-Builts shall be prepared on the original drawings or data sheets. Documents shall be re-drafted as

necessary to incorporate final information. Mark-up sketch, referencing, and other field marking

techniques are not acceptable.

Contractor shall provide as-Builts which are clear and readable in both full size and A3 reduction. In

the case of any not CAD produced drawings the Contractor shall prepare new drawings if the Project

Manager judges originals to be too damaged, deteriorated, or illegible.

As-Builts shall be issued as the next sequential revision from previous releases. The revision block

shall state “Certified As-Built”.

Electronic copies of the drawings shall be in electronic format suitable for reproduction on paper

using the Employer’s preferred software packages: PDF files and the original in CAD format.

All clouds, revision diamonds, and other interim control marking shall be removed from as-built

documents.

The Contractor shall provide soft copy source files of all as-built drawings. Soft copy files shall be in

agreed formats.

6.10. PROCEDURES

6.10.1. Erection Procedure

The Contractor shall submit copies of the erection procedure for all Plant, equipment and systems to

the Employer for information prior to such erection being carried out on the Site.

6.10.2. Pre-Commissioning Procedures

The Contractor shall prepare detailed standalone pre-commissioning procedures necessary to cover

mechanical and electrical completion, testing and pre-commissioning of equipment and systems to

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state of readiness for start-up and operation in accordance with the procedures, test details and

criteria contained in the Conditions of Contract and the Technical Specifications. The Contractor shall

review equipment systems and provide specialist assistance as required.

Pre-commissioning shall be carried out on a system by system basis. The Contractor shall, in

accordance with the procedures, test details and criteria referred to above, prepare a separate

procedure for each system to be pre-commissioned, bound in an A4 size file. It is important that

where Contractor packages/equipment pre-commissioning procedures are written that all relevant

Contractor drawings and documentation are included in the relevant procedure file. Each system pre-

commissioning procedure shall contain:

Title and system number to which the procedure refers.

Index

Status / approval signature sheet.

Equipment test record sheets including pre-commissioning test records.

The Contractor shall submit each system pre-commissioning procedures and all documentation for

review by the Employer not later than three months before the commencement of pre-

commissioning of that system. Each System pre-commissioning procedure shall contain all interfaces

tables necessary for the pre-commissioning and testing of that system.

6.10.3. Commissioning Procedure

The Contractor shall submit copies of the Procedure for Commissioning to the Employer for review

not later than three (3) months prior to the Commissioning.

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7. ERECTION, SUPERVISION AND CHECKING OF WORK ON SITE

7.1. GENERAL

The carrying out of all work on the Site included in this Contract shall be supervised throughout by a

sufficient number of qualified representatives of the Contractor who have had thorough experience

of the erection and commissioning of similar Works.

Contractor shall employ local unskilled and semi-skilled personnel in modality and quantity to be later

defined and shall properly provide training to the personnel.

The Contractor shall ascertain from time to time what portions of the work on the Site the

Employer/Project Manager desires to check, but such checking shall not relieve the Contractor from

the liability to complete the Works in accordance with the Contract or exonerate him from any of his

guarantees.

If at any time it appears to the Employer/Project Manager that the Contractor will be unable to

complete any Section of the Works in the time stipulated, then the Contractor shall, if required by

the Employer/Project Manager, carry on such work outside normal working hours and shall not make

any claims for any extra expense thereby incurred unless, in the opinion of the Employer/Project

Manager, the delay is due to causes for which the Contractor would be entitled to an extension of

time under the Conditions of Contract.

The Contractor shall satisfy himself as to the correctness of all connections made between the

apparatus supplied under the Works and apparatus supplied under any other contract before any of

the former is put into operation.

If the Employer/Project Manager shall certify that defects have been identified in the Works, the

Contractor shall, for the purpose of the maintenance after the completion of the Works provided for

by the Conditions of Contract, keep on Site supervisory staff of such numbers and for such periods as

the Employer/Project Manager may require.

The Contractor is to keep the site, on which he erects or stores plant, reasonably clean removing all

waste material resulting from the Works as it accumulates and as reasonably directed. On completion

of the Works the Site is to be left clean and tidy to the satisfaction of the Employer/Project Manager.

Any damage done to buildings, structures and plant or property belonging to Employer’s is to be

made good at the Contractor's expense.

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7.2. OVERALL TIME SCHEDULE

Proposed sequence for stop of the existing Units should be the following:

1. Unit 1

2. Unit 2

3. Unit 3

The rehabilitation of the Substation should follow the Units rehabilitation adopted sequence solution

in order to ensure a minimal interruption period for the units and power lines.

7.3. SUBCONTRACTED PLANT, MATERIALS AND LABOUR

The Contractor shall also provide to the Employer/Project Manager names and details of local

subcontractors FOR APPROVAL before such subcontracts are placed. Employer’s reserves the right to

withdraw its consent to local subcontract arrangements if such are considered unsuitable, but

consent will not be unreasonably withheld.

7.4. ACCESS TO MANUFACTURERS' WORKS

Access to the Contractor's and Subcontractors’ works shall be granted to the representatives of the

Employer/Project Manager for the purpose of inspection, testing and ascertaining progress.

7.5. TOOLS & EQUIPMENT FOR ERECTION, INSTALLATION & COMMISSIONING

The Contractor shall provide all special and standard tools and special equipment required to erect,

install and commission all systems and equipment of the plant to be supplied under this Contract.

7.6. CONTRACTOR’S EMPLOYEES

The Contractor shall fulfil all his obligations in respect of accommodation, feeding and medical

facilities for all personnel in his employ, in accordance with the responsibilities imposed on him by

the Specification or as necessary to ensure satisfactory execution of the Contract. He is also to comply

with the requirements of all local Statutory Employment Regulations.

The Contractor shall be responsible for all its personnel on site.

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7.7. ALCOHOLIC LIQUOR OR DRUGS

The Contractor shall not, otherwise than in accordance with the Laws of the Country, import, sell,

give, barter or otherwise dispose of any alcoholic liquor or drugs, or permit or allow importation,

sale, gift, barter or disposal by the Contractor’s Personnel.

8. TRAINING

The Contractor shall include the training of the Employer’s personnel to operate and maintain all

equipment efficiently and safely. There shall be no constraints on the number and category of

Employer’s staff to be trained on site.

The implementation of a structured training program for Employer’s operation and maintenance

employees constitutes a contractual obligation of the Contractor.

Courses shall concern the following areas:

Process,

Mechanical,

Electrical,

Instrumentation and control,

Civil structural,

HSE,

Project management,

At the end of the training courses each trainee will be interviewed by a professional expert in the

specific discipline to evaluate their degree of learning.

8.1. BASIC CRITERIA

The training shall be implemented through two different types of courses, namely:

Overseas Courses to provide the personnel at managerial level, with the basic

knowledge regarding the equipment, its technical characteristics and functionality, the

organization and management of the Power Plant and transmission system operation

and maintenance.

On Site Courses to prepare Project Managers, technicians and local operators about

power generation systems on all operational aspects such as:

o Equipment functionality,

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o Operation philosophy of the Power Plant systems,

o Maintenance (overhaul, predictive, preventive) and relevant procedures and

actions),

o Management activity.

Trainings are to be organized overseas in a country of the bidder’s choice and not necessarily home

country of the Consultant Engineer; preferably the manufacturer’s home country for turbine

manufacturer related training.

With reference to maintenance activity, particular importance shall be given to the problem-solving

approach and to the rules of the use of specific equipment and appliances.

Courses shall be held in English language.

Training activities shall be coordinated by a training specialist who shall monitor the implementation

of the training according to the program agreed.

All the trainees should assist to the tests planned for the commissioning.

8.2. OVERSEAS COURSES

8.2.1. Personnel involved

The training course shall be carried out for a period of not less than four weeks. The number of

trainees for each category is as follows:

Process - 3 trainees

Mechanical - 3 trainees

Electrical – 3 trainees

Instrumentation and supervision – 2 trainees

Civil structural – 2 trainees

HSE – 2 trainees

Project management – 2 trainees

The Contractor at the beginning of its activity shall prepare and submit to the Project Manager for

approval a detailed training program articulated according to the indicative scheme described in

details in the following paragraphs.

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8.2.2. General subjects

The first two weeks shall be devoted to lectures on subject related to general aspects of Plant

operation and maintenance such as:

Organization of operation and maintenance in order to achieve the maximum efficiency

and reliability of the Power Plant,

Power Plant operation and maintenance planning and management to maximize its

utilization factor,

Mechanical and electrical equipment characteristics and functions,

Control and instrumentation (DCS) theory,

Expected Plant performances,

Power Plant heat and mass balance,

HSE (Health Safety and Environment),

All the trainees participating to overseas courses will attend these lectures.

8.2.3. Specific subjects

During the last two weeks, the trainees shall be divided into groups on the basis of their specific

professional qualification to attend the courses on the following disciplines and the relevant specific

topics specified below:

• Electrical, Instrumentation, Mechanical and Process engineers: turbo generator operation and maintenance activity; cooling tower maintenance, pump motor servicing; compressed air system servicing; heat exchangers servicing; ejectors and gas extraction servicing; water treatment; chemical laboratory activity; corrosion protection; visual inspection of Power Plant machinery at Contractor's factory; systematic control of Power Plant performances, plant interlocks and logics, Turbine supervisory Instruments, Steam field control and communication system, DEHC, DCS. Visual inspection of Power Plant Instrumentation at Contractor’s factory, Turbine Supervisory instruments testing and simulation training.

• Civil and HSE engineers: process safety management, construction methodologies and procedures; quality control of construction site; technology of construction materials; environmental modelling; environmental impact assessment according to international standard procedures; seminar on latest environmental issues (Kyoto protocol and international conferences); monitoring systems for environmental protection; fire fighting system.

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• Project Staff: will attend the above mentioned courses for the part of their competence; training on the latest project management tools (i.e. Primavera, Microsoft Project software) for the planning and monitoring of the works implementation. Disaster management and internal procedures for organization, documents control

administration, communications, etc.

8.2.4. Costs

The Contractor shall bear the costs for training and for the supply of the documentation for all

trainees, in addition to the following items:

• air fare from/to Nairobi for each of the trainees, • suitable accommodation for each of the trainees,

8.3. ON SITE COURSES

8.3.1. Personnel involved

The course shall last at least five (5) weeks and shall involve about 8 engineers or technicians and 20

operators assigned to plant operation and maintenance activity.

The Contractor at the beginning of its activity shall prepare and submit to the Engineer for approval

a detailed training program according to the tentative scheme indicated in details in the following

paragraphs.

8.3.2. Training program

The program shall be articulated in two periods of three weeks and two weeks respectively:

During the first period courses, attended by all trainees, shall include:

o Tools and instrumentation use for predictive maintenance.

o Use of main tools for maintenance activities.

o Laboratory analysis methods and operation of laboratory equipment for

corrosion rate measurement and calculation, specimens preparing and

exposure to fluids, chemical treatments, chemical control after Power

Plant starting, failure analysis.

o Electrical maneuvers and procedure to change auxiliary service and to put in

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operation and to feed the MV and LV auxiliary services board by means of the

diesel generator; switchyard possible service; electrical protection

function.

o Firefighting system.

o DCS hardware and software.

o DCS and DEHC operation and maintenance.

o Training on the use of special tools and testing/calibration equipment.

During the second period the trainees, subdivided in the following groups, will attend

their courses according to the following scheme:

o Operators and Engineers:

o DCS operation;

o MMI management;

o RCE (record control event) management;

o Procedure for Power Plant operation in the following different conditions:

cold start, island operation, hot start, normal operation, emergency shut down, fault condition and actions;

o Procedures to put in safety conditions the equipment and to protect the

environment;

o Personal safety equipment;

o Procedures and methods to minimize the unavailability;

o Social and environmental monitoring;

o Disaster management;

o Maintenance Personnel and Engineers:

o Methods and instrumentation for physical measurements;

o Methods and instrumentation for actuators valve calibration;

o Electrical protection;

o Dosing pumps maintenance;

o Regulating devices;

o Procedures to put in safety conditions the equipment and to protect the

environment;

o Personal safety equipment;

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o Materials and procedures for repairing and replacing;

o Use of the workshop tools;

o Use of chemical laboratory equipment;

o Procedures and methods for disassembly and assembly of all equipment and

replacement of damaged components.

8.3.3. Costs

The Contractor shall bear the costs for training and didactical material for all trainees and shall supply

all on-site facilities including, but not limited to, documentation, meals, accommodation, etc.

8.4. HV SUBSTATION

HV Substation Design (4 Engineers at least for 2 weeks)

Overview of the properties of transmission and generation power systems;

Explain the power system dynamic and stable behavior including the transitions

between the different power system states;

Components and general behavior of the power system for generation and

transmission;

Basic power flow concepts and system analysis based on some system examples;

Power system modelling and analysis;

Learn computation techniques for fault calculations;

NOTE: All above mentioned points shall include this specific project as example/case study.

Protection and Control for Electrical Power Systems (4 Engineers at least for 2 weeks)

Introduction to a large electrical power system and overview on the general

requirements and objectives of transmission line protection;

Overview of the power system structure and behavior;

Different configurations of substations and their components and typical substation

automation system structures;

Interfacing the primary system (switchgear) with the substation automation system;

Understanding the most common protection schemes and basic requirements for

protection systems and the role of protection and station automation in power systems;

Protection philosophies, principles, typical application arrangements and tripping

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methodologies for different power devices. Study protection principles and evaluate the

appropriate protection concepts;

Principles and calculation rules for instrument transformers and describe the influence

of CT saturation;

Design protection schemes for transmission lines and select important protection

functions;

Coordinate different protection and establish selective and graded schemes;

Calculate the settings of several protection functions;

Specify and verify instrument transformers for use with line protection;

Design protection schemes for busbars, circuit breakers and transformers and select

important protection functions;

Prepare a protection coordination study Work intensively with advanced protective

relay applications. The goal is to familiarize technical personnel with the area of

numerical protection devices;

Role of substation automation in the power system management;

Describe the control, monitoring and protection functions in substations in some detail;

NOTE: All above mentioned points shall include this specific project as an example/case study.

Substation Automation (4 Engineers at least for 2 weeks)

Requirements of the signal data flow for utilities and the properties of the signal data

flow in a substation from the power process level (switchyard) through the bay and

station level up to the network level;

System Architecture Design for Substation Automation with IEC61850 – Application &

System Design;

Principles for SCADA and changing parameters such as database objects, signal texts,

measurement scaling and others;

Create graphic displays in SCADA e.g. single line diagrams, overview pictures, system

overview picture with new SA-LIB (new graphical user interface with zoom, panning and

decluttering functionality);


Telecommunication (4 Engineers at least for 2 weeks)

Introduction in IEC61850 standard structure - used protocol elements.

Need for a communication standard for substation automation and an overview of the

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communication in power systems and basics of communication and of functions in

substation automation systems including protection and the approach of IEC 61850

Summarize the concepts of data communication, protocols and standards

Features of the most common standardized protocol used in communication systems of

power utilities and especially in substations

List and compare the essential features of all these protocols and explain the use of all

these protocols

Configure NCC communication protocols IEC 60870-5-101,104 and configuration of

device hardware CPU and interfaces (Ethernet, GPS ...).


HV Switchgear (4 Engineers at least for 2 weeks)

Design criteria and operational considerations,

Switchyard arrangement;

Safety considerations;

Steel structure design and detailing;

Use of relevant software in design;

Substation Building;


All overseas trainings shall be performed at manufacturers’ home country.

The Contractor shall be responsible for the following costs; :

Training venue

Trainers

Economy class return air ticket for the Employer’s staff

Local transportation

Meals during the training

Full board Hotel accommodation

Addendum - Kenya Electricity Generating Company No... · present 220 KV Overhead Lines connections...

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