VOLUME 3 DETAIL DESIGN - etenders.gov.za Rev3 201701... · Extend Qunu SS to be equipped with 2 x...

Volume 3 - Detail Scope of Work Page 0

VOLUME 3

DETAIL DESIGN

SOUTHERN REGION PROJECT TITLE: Qunu 132/22kV Substation Refurbishment Rev. 3 PROJECT No : ST-STM-0907-1566-00001

INDEX DESCRIPTION PAGE Attached Y/N

1. Specifications/Standards 1 Y 1.1 Description of Works 2 Y 1.2 Setting Out 3 Y 1.3 Site Work 3 Y 1.4 Control Building 6 Y 1.5 Steelwork Assemble and Erection 11 Y 1.6 Pricing Specification 16 Y 1.7 General 17 Y 1.8 Quality Control 17 Y 1.9 Project Risk Analysis A1 Y 1.11 Safety Specification A2 Y 1.12 As-Built Information 18 Y

Annexure 1: Risk Analysis 19 Y Annexure 2: Safety Specification 22 Y

SCOPE OF WORK 1. Extend Qunu SS to be equipped with 2 x 132kV line bays, 2 x double tubular busbar bays and 2 x

20MVA, 132/22kV transformer bays. Test and commission the new substation. 2. The long lead primary material listed in Volume 4 shall be supplied by Eskom. 3. The Contractor shall supply all the short lead time material required to construct and complete the

Qunu 132/22kV Substation refurbishment. 4. All work shall be carried out in strict accordance with the latest revision of Eskom Standards and

Specifications. 5. The secondary plant (Protection, Telecommunications, Scada and Control) shall be supplied, installed,

tested and commissioned by Eskom. Revision Details: Rev. 3 Revised by: B Grib

Rev 2: Update on Civil & building works 2) Trfr no changes updated 3) Outage requirements changed 3) MPA strength of concrete updated 4) No Fire Barrier needed Rev 3: Split package between Bulk Civil Works and Primary Plant package

Compiled By Project Engineer Name: M Stoltz Tel: (031) 714 2553 Date: 16 Jan 2017


PROJECT SPECIFICATION FOR THE SITE WORKS

1. Specifications/standards

All works are to be carried out in accordance with the listed standards. The project specification is specific for the Southern Region and these requirements will overrule any duplication in the national standards.

Doc No. Rev Doc Title Attached

Part 2 Earthing - Standards

SCSASABK2 0 Standard: Substation earthing. Drawings (D-DT-5240) No

Part 7 Substations - Standards

SCSASABB5 1 Standard for road works for sub-stations and access roads

No

SCSASABF3 0 Distribution Group's specific requirements for the use of furniture in substation buildings

No

SCSASABK6 0 MV cabling in substations Drawings No

DISASAAQ1 5 Quality checking of distribution substation construction before handing over for commercial operation

No

Part 22 Cables - Standards

SCSASACA1 0 Distribution Standard Part 22: Cables Section 0: General Information and requirements for low-voltage cable systems. Drawings

No

Asbestos Handling - Standards

ESKPAAG5 1 Distribution Standard: Requirements for the safe processing, storing, removing and handling of asbestos and asbestos containing material, equipment and articles

No

SANS - Standards

SANS 1200A General No

SANS 1200C Site clearance No

SANS 1200D Earthworks No

SANS 1200DB Earthworks (Trenches) No

SANS 1200LC Cable ducts No

SANS 1200L Drainage No

SANS 1200G Concrete No

SANS 1200H Steel erection No

SANS 1200MJ Civil Eng. Construction of segmented paving No

SANS 1058 Quality of concrete paving blocks No

SANS 920 Reinforcement No

SANS 763 Galvanizing No

SANS 227 Face bricks No

SANS 82 Bending of reinforcing No


SANS 0167-1984 Welding No

General

ESKARAAG4 All work is to be carried out in strict terms of Operating Regulations for High Voltage Systems –. With special reference to (5.03.6.3) & Prohibition Notice’s

No

1.1 Description of works

Qunu 132/22kV Substation is an existing substation in Eskom Distribution Southern Region. The substation is currently supplied from Tyalara and Vuyani substations via these two 132 kV lines. The substation consist of 1 x 20 MVA transformer. This arrangement does not comply with the Reliability guideline for the Region. There were also other refurbishment triggers which led to the release of the Qunu substation refurbishment. The scope of work is as follows: Stage 1 – Civil Works and Control Room: A civil contractor is to be appointed to extend the existing Qunu substation terrace.

• The local TSC is to barricade the existing Live Equipment with permanent barricading. • The existing outside diamond mesh fence to be replaced with steel palisade. • The Civil Work in this contract will include extension of the earthmat for the new

platform and all casting of new equipment foundations. • The contractor is to have a responsible person on site during construction that can

take a permit as issued or approved by Eskom. The contractor will be responsible for the extension of the control room.

• The existing control room will remain operational during the extension of the structure. • A permanent access to the existing control room will be maintained during all stages

of the control room extension. • The door to the existing control room will be locked at all times. Access to the existing

control room during the construction phase will be under supervision only. • The applicable electrical circuits in the existing control room must be isolated and then

earthed away from the area of works prior to the commencement of construction. • Ablution facilities must be provided as the existing facility will be demolished in the

early stages. • The contractor will provide a responsible person on site to supervise the construction

of the extension until completion or until released by the Project Manager. Stage 2 – Steelwork and Equipment: While the existing substation is energised the following steelwork and equipment can be installed:

• The new 132kV terminal structures & Landing Gantry • Both 132kV HV Feeder Bays (Tyalara 1 Complete – Vuyani 1 partial) • Trfr No2 HV and MV Bay • The new 22kV Column and Beams • It is recommended that a Live Line Team connect the new 22kV Beams to the

existing 22kV busbar structure as one side would be live. Alternatively the work must be done under direct supervision of an authorised TSC representative.

• All stringing, jumpering, cabling etc can be done prior to any outage. • The Tyalara Feeder can be isolated and rerouted to the new feeder bay. • The 132kV Buscoupler can be isolated and the Old Tyalara feeder bay can be

dismantled. • The Tyalara no1 HV Feeder and Trfr No2 Busbar Bays can be equipped while the

substation is supplied by the Vuyani 132kV Feeder. On the 22kV system, busbar 1 and 2 will each be split while the existing Trfr No1 is still energised.

• The Tyalara no1 HV Feeder & Trfr No2 can be commissioned prior to any outage on Trfr No1.

Stage 2 – Outage:


In order to complete the construction work on the s ubstation, a partial outage will be needed to connect the 22kV Busbars and disconnect t he Trfr No1 22kV Jumpers. The supply can be restored to the 22kV system via Trfr No2. In order to maximise work during the outages multiple construction teams will be required on site. During a 12 hour outage the following work will be done:

• The existing Transformer Bay No1 will be disconnected from the 22kV busbar. • All the 22kV Busbar jumpers between the existing and the new section will be installed

At the end of the outage the new Trfr No2 will be energised through a section of 132kV busbar No1. Supply will be coming from the Tyalara 132kV feeder only. Stage 3 • Reroute the Vuyani 132kV feeder to the newly installed terminal structure. • The existing closing span to the substation including the wooden H-Poles is to be dismantled. The local TSC will ensure the barricading around the newly energised equipment is adequite. This will allow for the dismantling and scrapping of the old transformer bay equipment (Excluding the Trfr, NEC & 132kV CT’s). Supply must then be switched to busbar 2 with busbar 1 isolated and earthed. This will allow the construction team to complete busbar 1.

1.2 Setting Out

The Contractor is to familiarise himself with the site conditions. The benchmark (BM) must be constructed or indicated by the Clerk of Works, which shall serve as a reference level and must be clearly marked. Before any construction work may commence the contractor must set out the corners of the internal and external fence from the X Y axis. The position of the main gates must line up with the access road.

1.3 Site Work

1.3.1 EXCAVATIONS Note: Substations are deemed as “restricted areas” and the use of plant and/or machinery for construction activities such as excavations or for the removal of rubble is not permitted without prior approval [i.e. only hand digging and jackhammers are allowed] Excavations required for foundations, earthmat, cable trenches, road and stone kerbing etc. are included in the respective items, these are measured as supply and install complete. Only the extra-over excavation in rock is measured separately. Any variance between the actual and measured quantities must immediately be brought to the attention of the Project Manager, in writing, failing which; all excavations shall be measured and paid as per the Bill of Quantities [BOQ]. Foundations are to be dug as close as possible to the required size. Where the depth of the foundation is deeper than 1.5m, shoring shall be used in accordance with OHS Act. The bottom of all foundations shall be level and cut squarely with the sides of the foundation. Compaction of the bottom of the foundation and backfill shall be as per 1.3.2 COMPACTION.

1.3.2 COMPACTION All compaction shall be compacted at OMC to a density of at least 93% of Mod. AASHTO maximum density for cohesive soil or 98% in the case of non-cohesive soil, all fill shall be compacted in layers not exceeding 100mm and each layer shall be compacted to the above density. If the Project Engineer is not satisfied with the compaction, he will request that the contractor have a compaction test done by an approved company. If the results are successful, Eskom will be liable for all costs. Should the results fail, the contractor will be liable for all costs and the costs of any re-test required. Once completion of the preparation work involved in the construction of all equipment and steelwork foundations is imminent, prior to the concrete being cast, the designated Clerk of


Works or his delegated representative shall be given satisfactory advance notice of the need to visit site to inspect this form work, ie. setting out, excavations, foundation centres, levels, alignment, reinforcing, earth connections, etc. It is essential that this stage be observed as a critical “hold point” by the contractor involved and no further work shall continue on this phase of construction, until the necessary inspection has taken place and the work approved accordingly.

1.3.3 CONCRETE All equipment foundations and bases shall have a minimum strength at 14-day of 25MPa with a nominal stone aggregate size of 20-25mm. Transformer foundations shall have a minimum strength at 21-day of 25MPa with a nominal stone aggregate size of 20-25mm. Blinding and strip footings shall have a minimum strength at 7-day of 15MPa. Any additives to the concrete shall have the approval of the Project Engineer. All tolerances shall be for “Degree of Accuracy II” as per SANS 1200G. Final strength after 28 days should not be less than 25MPa. Samples of all stone, sand and water to be used in the concrete shall be tested and approved prior to construction commencing. The laboratory results must be sent to Eskom for approval by the Project Engineer, if a non-approved supplier is used to supply the above material. When concrete is mixed on site, cube tests must be made available for the Project Engineer to have tested if required. If cube tests fail, all foundations already cast will be tested at the contractors cost. The timing of the test shall be at Eskom’s preferences (i.e. random). One cube of each set shall be tested at 7 days and the other at 28 days. The result shall be forwarded to the Project Engineer for approval. Concrete hardener ABE Korocron shall be applied to the concrete floor area of the oil containment area. Apply as per the suppliers specifications.

1.3.4 FORMWORK The finish of all exposed surfaces of concrete shall have a smooth “off-shutter” finish and be free of all blemishes, honeycombing and irregularities.

1.3.5 GEO-PIPES There are no Geo-pipes applicable to this project. However, should these be required Tee-pieces are to be used to interlinked Geo-pipes and End-caps to seal off the start. Leave the discharge ends open. Where the geo-pipes are installed on the inside of the perimeter fence, the trench dug for the earthing must not be closer than 600mm from the fence. The round copper will be installed on the outside edge, as close as possible to the fence. Backfill 100mm of soil before the geo-pipe is installed.

1.3.6 OPTIC FIBRE PIPE Use Kabelflex DN110 pipe for the piping of the optic fibre. The supplier of the pipe is Nextube. Always leave draw wire in the pipes where the optic fibre will be installed.

1.3.7 OIL CONTAINMENT AREA DRAINAGE Use 75mm diameter uPVC class 4 pipes for the water drainage pipe from the valve chamber of the oil containment area. Where uPVC pipes cross a road class 6 drainage pipes are to be used. Concrete piping with an internal diameter of 300mm is to be used for active drainage system from oil containment area to oil dam. Each joint of the concrete pipe must have an approved rubber seal.

1.3.8 REINFORCING All bars shall be neatly bent cold, accurately fixed and securely wired in the shape and position as shown on the drawings. The reinforcing shall be free of loose rust and grease. Unless otherwise stated on the drawings the concrete cover for all reinforcing shall be 40mm or as specified on drawings. Reinforcing for transformer plinths and slipways to be weld mesh ref. 6.17 sheets or self-tied to 6.17Spec. All reinforcing overlaps shall have a lap length of 350mm.


1.3.9 H.D.BOLTS All H.D. Bolts to be fixed, using steel templates or approved wooden templates. The Clerk of Works shall inspect the position of H.D. Bolts before concrete is poured. When removing holding down bolts from a foundation the bolts must be cut off 25mm below finished level of concrete and the holes must be finished with a 25MPA floated concrete grout. All H.D. Bolts are to be painted with one coat of silver paint.

1.3.10 REMOVING OF CONCRETE BASES Foundations, which are to be removed, must have the resulting holes backfilled and compacted as per 1.3.1 EXCAVATIONS . Foundations, which are to be removed to 100mm below ground level, must have their H.D. Bolts cut off at concrete height. The earth tails are to be removed to 100mm below ground level. If an old foundation clashes with any of the new works the old foundation must be removed in such a way that will allow the installation of the new foundation. If an existing foundation is to be re-used, the existing H.D. Bolts are to be cut off 10mm below the top of the foundation. The hole left by the removed H.D. Bolt must be closed with a 25MPA floated concrete grout.

1.3.11 CHEMICAL ANCHOR DETAILS Should chemical anchors be required Ramset Chemical Mortar and studs should be used to act as holding down bolts for equipment supports. The stud must be a M24 x 500mm galvanized threaded rod, supplied with two nuts and two washers per stud. Install the stud and Ramset Chemical Mortar to the supplier’s specification. After installation of the stud, a 100mm of thread on the stud must protrude above the surface of the foundation.

1.3.12 BUND DRAINAGE OUTLET PIPE (GALVANIZED) A 400mm length of 75mm diameter galvanized pipe, with 30mm of thread on 1 end and a 150 x 150 x 3mm thick galvanized steel plate welded to it, 120mm from the non-threaded end. This plate shall be built into the bund wall. All welds to be seal welded.

1.3.13 GRATING & SUPPORTS An assembly and detail drawing is included. All grating to be MENTIS RS80 Rectagrid with bearer bars 30mm x 4.5mm. Grating to be open-ended banded along discontinuous edges. All dimensions to be checked prior to manufacture. Support Steelwork to be 500x25x5mm flat galvanized iron. Welding is to conform to SANS 0167-1984. All welds to be seal welded. Steelwork to be hot dip galvanized to SANS 763 for coastal areas. All steelwork to be fabricated erected and levelled to a tolerance of 1.5mm.

1.3.14 STONING The existing stone layer must be carefully removed to ensure it remains “clean” and stockpiled separately for later re-spreading. No stone will be accepted if mixed with soil. The final yard stone layer is to be 100mm thick [min]. This must be the last activity to be done in the construction of a new substation.

1.3.15 GROUTING Grout must be squared with the footing.

1.3.16 SEALANT Sikaflex-pro 2HP joint sealant must be used in accordance to supplier’s specification, for the sealing of the oil containment area.

1.3.17 OIL ABSORBING CUSHIONS “Drizit cushions” can be purchased from “Cape Chemical Industries”. Tel: 041-4513341 Two cushions must be installed per valve chamber.


1.3.18 WEED KILLER (HERBICIDE) Prior to spraying of weed killer, the yard is to be cleared of scrub. For pricing purposes, the spraying of weed killer includes the clearing of scrub. The type of weed killer to be used is Edge SC and red dye. Spray weed killer according to manufacturer’s specification.

1.3.19 BERM The new Berm outside the existing substation yard shall be part of the Bulk Civil works contract.

1.3.20 PREFORMED CONCRETE KERBING BLOCKS Pre-cast kerbing blocks to be used for road and stone kerbing as well as cable trenches as detailed on: Civil drawing: D-EC-1977 Trench cover: D-EC-1735 sheet 1 & 2: 0,75m Manufacture the blocks with 30MPa concrete. Stone kerbing is to be bedded in a 75mm thick concrete bed and a 75mm thick side layer. Road and cable trench kerbing is to be bedded in a 100mm thick concrete bed and a 100mm thick side layer. For costing purposes, the excavation to be done and concrete needed to install kerbing, is to be included with the quantity to “supply and install kerbing”.

1.3.21 OIL CONTAINMENT AREA WALLS, JOINTS AND STEPS Face bricks are to have a minimum of 20% water absorption. All joints constructed with 10mm thick mortar (1:4) cement: sand raked finish. Containment walls shall be capped with a roll course. Steps constructed of face bricks, built on the 100mm internally slab and an externally on a 150mm concrete foundation. Step risers to be maximum 180mm and treads to be 220mm wide.

1.3.22 RETAINING WALLS There are no retaining walls applicable to this substation. However if there is a requirement during the course of construction, Terra Force blocks shall be used to construct retaining walls. The blocks are to be installed according to the manufacturer’s specifications. Terra Force must be priced with main offer and a similar product can be offered as an alternative with the tender document. Before the installation of Terra Force Wall a design must be submitted to the Project Engineer which has been approved by a Civil Engineer.

1.3.23 PAVING BLOCKS Use 80mm thick type S-B geometrical interlocking grey paving blocks made out of 35MPa concrete. Install the paving blocks according to the manufacturer’s specifications. Paving blocks are available from Inca. Inca must be priced with main offer and a similar product can be offered as an alternative with the tender document. Paving blocks shall be applied to the access road and to the area around the control building.

1.4 Control Building

1.4.1 GENERAL All dimensions and levels are to be checked on site prior to the commencement of construction. The drawings are not to be scaled from. All notes and specifications are to be checked by the Project Manager and, if in doubt, must refer to the Project Engineer for instruction and/or clarification. All finishes and fittings are to comply with Eskom standards where applicable.

1.4.2 CONSTRUCTION The existing control room is to be extended as shown in the drawings. The construction will consist of 280mm face-brick exterior walls on strip footings. The floors slabs will be 100mm RC slabs on compacted beds and finished level with the existing floor. The existing sheet


roof will be extended with a minimum 300mm or one full profile section of the sheet lap. The new DPM is to be lapped under the existing DPM by a minimum of 300mm. The front wall of the existing control room must only be demolished once the building is water tight. This is to facilitate the functioning of the control during the construction phase. The Project Manager is to ensure that safe access to the control room is possible at all stages of the construction process. The Project Manager is to ensure that all workers are supervised during construction and that they are kept away from the live components of the control room. The battery room and new toilet will be built simultaneously with the control room extension. The existing toilet is to be demolished and a new battery room built. The battery room floor is to be no less than 375mm lower than the FFL of the control room. The roof over the control room is to be extended over the battery room. The sheeting and DPM must be lapped under the existing sheeting no less than 300mm. The floor of the battery room is to be coated with a fully bonded acid resistant epoxy coating and laid to a fall towards the basin side wall. The door is to be provided with a ventilation grille with air filter and the room is to have an extraction fan according to Eskom specifications. Water for the basin is to be provided by a new water butt to be raised so that the level of the butt outlet is at least 100mm higher than the faucet outlets of the basin or the water but must be fitted with a serviceable pump located beneath the tank and connected to the DC emergency supply. A new toilet is to be built to the rear side of the control room. The current sanitation system is to be maintained and care must be maintained in its removal during the demolition of the existing toilet. A new WHB is to be added to the toilet which is to be fed from the existing water butt. The existing butt needs to be raised so that the outlet is at least 100mm above the WHB outlet or fitted with a serviceable water pump. The control room roof is to be extended over the new toilet with the sheet and DPM to be lapped under the existing sheet by at least 300mm.

1.4.3 FOUNDATIONS The excavation, compaction, reinforcement and concrete are to comply with the relevant standards as indicated under SANS standards of this document and to the relevant sections of this document as indicated under 1.3 Site Works . The Project Engineer is to check the condition of the trenches prior to the pouring of concrete. This stage is to be a dedicated “hold point” and no further construction is to take place until the approval of the Project Engineer has been gained. Where new foundations abut existing foundations it is essential that the earth around the new foundation be disturbed as little as possible and that the new and old foundations are separated by 10mm Jointex adhered to the existing foundation.

1.4.4 FLOORS AND RAMPS The floors are to comply with the relevant SANS standards as indicated in this document. The slabs must be 100mm thick reinforced concrete with strength at 21 days of 30MPa and an average aggregate size of 19mm with 617 mesh reinforcing to have a minimum cover of 40mm both above and below. The earth beneath the floors is to be prepared with min 150mm rip and re-compact material compacted to 95% mod AASHTO with 150mm G7 compacted to 95% mod AASHTO over with min 150mm G5, compacted to 97% mod AASHTO to the level required beneath the slab. Levels are to be checked prior to the pouring of the concrete and this is to be considered a “hold point” with no further construction until the Project Engineer’s approval has been obtained. The pouring of the slabs is to be supervised by either the Project Engineer or another responsible person as nominated by the Project Engineer. A 250 micron DPM is to be laid beneath the floor slabs and down the sides of the trench walls to the U/S of trench floor blinding. The DPM is to be lapped under the DPC at the wall edges.


All concrete is to have a steel floated finish with all protrusions removed and ready to receive the floor covering. The existing floor covering in the control room is to be removed. The new floor and existing floor in the control room are to be covered with a fully bonded hardened screed. Concrete floors to new trench cables are to be built to the same specification as the typical floor. The new ramp is to have a brush coated finish with the slope of the ramp not to exceed 1:10. The levels of the ramp are to be checked on site prior to construction and any alterations approved by the Project Engineer. Steps to the toilet are to have a riser no greater than 180mm, brush finished and reeded at the nosing. The ramp and stair edging are to be smoothed to a wood float finish. A metal handrail is to be bolted to the sides of the ramps as indicated on the drawings. The bolts should allow for removal of the railings in the event of delivery of equipment. The handrails are all to be "Valmetex" or equal approved stanchions and rails with a minimum height of top rail 1000mm high above finished floor level.

1.4.5 WALLS All brickwork is to comply with the relevant SANS standard as specified in this document. Walls are to be 280mm thick with FBS imperial size brickwork to match the existing. A sample of not less than 10 typical bricks of a type selected by the Project Manager are to be sent to site for comparison with the existing brickwork at least 8 weeks prior to the required delivery date. The jointing of the brickwork must also match the existing method with the typical joint being 12mm. The inner skin is NFS imperial size. The outer or cavity face of the inner skin is to be bagged and painted with approved damp proofing paint. Car must be taken to ensure the cavity is kept clear. Cavity is to be checked and raked clear after every course is laid. Weak mix mortar is to fill the cavity up to the underside of the DPC. 75mm wide GMS Brikforce is to be laid to each of the first 4 courses below floor and each of the top 4 courses below the wall-plate and to every third course in-between. Wall ties are to be GMS Butterfly type, 5 per sq. metre in walls, 300 c/c at jambs.

220x150 terracotta airbricks fitted in pairs with insect guard mesh are to be located at the positions shown on the drawings. A 350 micron DPC is to be installed in line with the existing DPC, in the case of the control room and new toilet and in line with the top of the slab in case of the battery room. The DPC is to lap over the DPM. DPC is to be fitted around openings as indicated on the drawings. The walls below DPC are to be FBX to match the existing on the outer face to at least 2 courses below ground level. Below this, and the inner skin and the trench walls are to be NFX clay bricks with the outer, soil facing skin bagged and painted. New internal walls are to be plastered. Between new and existing plasterwork a joint is to be raked into the plaster not less than 10mm deep. This joint can be filled with a flexible decorators sealant and painted over. Plaster is to be 1:1:6 (cement:lime:sand) to a smoothed to a steel float finish. The plaster is to be fully cured prior to priming and painting.

1.4.6 DOORS AND WINDOWS Doors are to be galvanised steel, painted and fitted to Eskom Specification. Hot Dipped GMS security gates are to be fitted to doors and protective GMS gratings to windows. Ironmongery is to be to Eskom Specification.


1.4.7 ROOF AND CEILINGS The roof is to match the existing 6mm Bigsix Fibre cement roofing profile and painted accordingly. Where new sheets are required there is to be an overlap of at least one ridge profile or 300mm whichever is the greater. Beneath the purlins is to be laid a 250 micron DMP lapped under the existing DPM. The DPM is to extend past the edge of the outer face of the wall by at least 150mm or to edge of the facia. When fitting the new DMP the purlins and sheeting must be removed to the next available truss to allow for the lapping of the membranes. The pre-fabricated timber roof trusses shall be designed by a registered professional Engineer and shall be in accordance with SABS 0160 and 0163. The wind loading shall be as determined in terms of Clause 5.5 of SABS 0160. The applicable terrain category shall be taken as Category 2. All prices shall be deemed to include the cost of the registered professional Engineer. Tenderers are to allow for all truss and support elements in their prices, i.e. the pre-fabricated trusses have been measured and billed in accordance with the guidelines of the Standard System of Measuring Building Work (Sixth Edition). Roof timber is to be treated against insect attack with CCA or similar. Trusses are to be manufactured offsite to match the existing. The rafter extensions over the battery room and toilet are to be built on site. Timber sections are to be joined with Gangnail or similar and bolted where indicated by the design engineer. Roof purlins are to be nailed to the underlying trusses at centres shown but not exceeding 1200mm. The sheeting is to be fixed through the ridge of the profile with GMS J-Bolts and washers to each of the purlins; adjacent to each truss location but no greater than 450mm. 38x50mm ceiling brandering is to be nailed to the truss tie beam at centres no greater than 400mm and along the edges of the walls. 4mm Nutec fibre cement sheeting is to be screwed to the brandering with phosphorus coated screws at centres no greater that 150mm. The screw heads are to be primed and filled prior to painting.

1.4.8 PAINTING All surfaces are to be clean dry and dust free before painting begins. Wall and ceiling painting is to be composed of 1 coat Plascon Plaster Primer, 1 Filler coat and 2 finishing coats of white Plascon Wall & All or similar approved. Final paint coats to be applied only after commissioning of Electrical Equipment. Galvanised Metal doors are to be prepared with Galvkleen or similar followed by 1 coat calcium plumbate primer, 1 coat universal undercoat, 1 coat gloss enamel. Colour to be to Eskom standard specification.

1.4.9 SANITARY AND SEWERAGE As far as possible the existing sanitary wear including the sewerage system is to be carefully removed and reused. A new seat and lid must be supplied in white and fitted according to manufacturer’s instruction. Fitting to the battery room and toilet are to Eskom specification and must be fitted to manufacturer’s instructions.

1.4.10 WATER RETICULATION Water to the battery room and toilet is achieved via the roof collection tanks. One is the existing tank and this feeds the new toilet. There must not be a connection to the WC as this system is a dry system and must not have any water added. The WHB is plumbed directly to the tank. Both tanks must either be supplied with a pump fixed to the wall beneath the tank that is fully serviceable or the tank outlet must be a minimum or 100mm above the level of the faucet outlet for a pipe run of less than 10m.


1.4.11 FIRE The control room and battery room must be fitted out in accordance with the fire regulations based on Section TT and WW of SABS 0400 – 1990 and Eskom specifications. This is to include signage, extinguishers, emergency lighting etc. The wall between the battery room and control room must be fully sealed with bricks and mortar to the underside of the roof sheeting to prevent fire spread from either room to the other. No fire-barrier will be erected between the existing 132kv transformer and the Control room, since the control room does not have any windows in the wall facing the transformer.

1.4.12 D RAINAGE The grey water systems must be connected to a soak-away as indicated on the drawings. The battery room drain must have an acid neutralising catch-pit fitted inline. Rainwater drainage must be connected to the soak-away as indicated on the drawings. The soak-away must be sized and constructed in accordance with the local storm water attenuation directives and must not discharge directly on to any adjacent property. The soak-away must not be located within 5000mm of any foundation structure. Length, depth and location of soak-away to be confirmed by the Project Engineer on site.

1.4.13 ELECTRICAL The building electrical and telephone ducting installation shall be the flush mount type. The building electrical installation shall be completed in strict accordance with the relevant project drawings, SANS 10142 – ‘Code of Practice for the Wiring of Premises’, applicable electrical specifications and any other pertinent design requirement.

NB. A form of compliance certificate must also be issued by the contractor involved in the LV installation in the substation building, to ensure same complies with the requirements of SANS 10142 in every respect applicable. Emergency lighting is to be installed in accordance with Eskom Specification and the relevant Cod of practice.

1.4.14 CONTROL ROOM CABLING AND PANEL ARRANGEMENT All electrical equipment in the substation building shall be installed as indicated on the relevant project panel layout drawing.

Cable entry from the substation yard into the control building shall be provided via the existing cable trenches.

All armoured cables shall be terminated by means of mechanical glands, fitted complete with earth rings and shrouds. The cores shall be identified and terminated with approved spade and pin type connectors, as indicated on the relevant drawings. All cables shall be identified at both ends by punched or engraved brass tags attached to the cable with galvanized wire.

1.4.15 AC AND DC DISTRIBUTION AC Supply The 400V AC supply to the control building shall be provided from the low voltage chamber of the NECRT unit in the substation yard, where applicable.

The AC distribution board shall comprise a single unit, per Eskom (Eastern Region) specification, for securing to the control room wall. The board shall be the surface mount type, with appropriately hinged doors and must be manufactured in accordance with SANS 1765 for boards having a short circuit rating up to and including 10kA. A certificate of compliance must also be issued by the manufacturer and supplied with the unit, to ensure same complies with the requirements of SANS 10142 in every respect applicable. All cables connected to it shall be secured in place via a suitable cable tray mounted directly above or


below the unit. Reference must be made to the relevant project drawings for details of the positioning of the AC distribution board. DC Supply The 110V DC supply to the panels shall be provided from a DC distribution board comprising a single unit, per Eskom (Eastern Region) specification, for securing to the control room wall. This board shall be of the surface mount type with appropriately hinged doors and must be manufactured in accordance with SANS 1765 for boards having a short circuit rating up to and including 10kA. A certificate of compliance must also be issued by the manufacturer and supplied with the unit, to ensure same complies with the requirements of SANS 10142 in every respect applicable. The DC distribution board shall be supplied from the combined 110v DC battery / battery charger suite. All cables connected to it and any associated equipment, shall be secured in place via suitable cable trays mounted directly above or below the respective units. Reference must be made to the relevant project drawings for details of the positioning of the DC distribution board.

1.4.16 SECURITY SYSTEM A security system is to be installed to Eskom specifications and in accordance with the manufacturers and installers specifications.

1.5 Steelwork assemble and erection

Structure shall be erected, aligned, squared, plumbed and levelled to an accuracy specified in SANS 1200 H (6.2.2.C) 2 – II All steelwork assembled according to Eskom supplied drawings. No welding other than that specified on the drawing, or cutting of steelwork after galvanizing, shall be permitted whatsoever. All equipment supports and sub-station steelwork must be galvanized to SABS ISO 1461 specification and delivered to site as complete bundle sections, in accordance with the appropriate drawings established for the relevant item. No damage to the galvanising will be accepted.

1.5.1 ERECTION OF EQUIPMENT AND STEEL Equipment and steel shall be erected according to manufacturer’s specification and substation drawings. Tubular busbar post insulators may be shimmed for alignment using stainless steel shims as per drawing D-EC-2112 Rev 0. Isolators and breakers final settings must be checked by Eskom before commissioning. Various items of equipment, each with unique differences (size, type, functional purpose, rating, etc.) are to be installed under the scope of work for this project. The following points must be taken into consideration when installing such equipment; (i) Each item of equipment shall be installed in position in accordance with the applicable detailed design drawings, specifications and sound engineering practices. (ii) Each item of equipment shall be erected and plumbed vertically into the correct position, central to the applicable setting out line established for the specific bay, which must be accurately referenced to the official setting out lines established for the substation indicated on the relevant drawing (Level & Drainage). All applicable structures shall also be checked for level prior to any equipment being secured into position.

1.5.2 RE-USE OF EQUIPMENT SUPPORTS, COLUMNS, BEAMS AND EARTHPEAKS When steelwork is re-used all the nuts and bolts must be replaced with new, of the same type and size nuts and bolts. The nuts and bolts must be hot dip galvanized .

1.5.3 BUNDLING NOTES Decommissioned steelwork bundles must be tied with 3mm thick galvanized wire at 500mm spacing to form manageable bundles. Use 3mm thick aluminium labels to label each bundle. Each bundle must be labelled to identify the type of structure it belongs to and numbered to ensure that all the individual bundles can be placed together to form that


specific structure. The punched letters on the labels must be 1mm deep, 4mm high and 3mm wide and maintain 2mm spacing between words.

1.5.4 EARTHING All earth-tails installed and connected as per detail on the drawings. The earth tails are to be installed at a min. depth of 500mm. For standard earthing specification, see drawing D-DT-5240. The specification mentions crimping of earthing, no crimping is allowed. All joints to be silbralloy brazed and painted with bitumen paint. All earthing connections must be tinned. All tinned copper must be treated as described prior to making a connection: Wash and brush tinned area in water. Apply thin layer of non-oxide grease only to tinned areas facing galvanized steelwork. Where connection is made to galvanized steelwork the surface shall be coated with non-oxide grease prior to bolting. Working standards must be adhered to when earthing equipment that is in service. All column earthing must have an 18mm dia. hole drilled in the centre of the column HD bolt plates. The columns are to be earthed to the main earthmat using 50 x 3mm flat copper to the 16mm dia. holes. 50 x 3mm flat copper is to be used to interlink the HD bolt plates inside the foundation. See the earthmat layout drawing for the direction of the earth-tails. For the earthing of transformer surge arrestors, one 50 x 3mm flat copper earthtail is connected to the earthing square on top of the transformer plinth and run up the transformer connecting to the surge arrestor bracket. In cases where individual surge arrestor brackets were used, the earthing of these brackets is to be interlinked and connected to the earthing square on top of the transformer plinth. If no earthing point is available on the transformer, earthing points are to be indicated by the Project Engineer. When earthing the neutral bushing of the transformer the section of earthing between the neutral bushing and the current transformer is to be insulated. If the current transformer is of the coil type, the insulated copper is to extend 100mm beyond the current transformer. Heat shrink is to be used for the insulation. Main earthmat runs on the inside and the outside of the security fence. Bring the earth tail up to the fence post from the main earthmat on the outside of the security fence and secure it to the fence post by using the earthing hole on the post. The fence post must also be connected to the main earthmat on the inside of the security fence, but not by utilizing the earthing hole on the post. The earthing tail from the main earthmat on the inside of the security fence must be brazed to the earthing tail running to the fence post from the main earthmat outside the security fence. Braze it at a point below ground level that would utilize the least amount of flat copper. Create a t-joint when the brazing is done.

1.5.5 FLEXIBLE LEADS 300mm x 300A flexible copper leads with 16mm and 12mm lugs are to be used for breakers and current transformers. 300mm x 150A flexible copper leads with 16mm, 12mm lugs and gate clamps are to be used for gates. Note: All lugs to have heat shrink covering of 70mm. Gate clamp: D-EC-1960. (Gate clamp must only be used if there is no earthing point on the gate).

1.5.6 DROPPERS AND STRINGERS This incorporates the stringing and attachment of all conductors to all of the equipment specified in the scope of this project, as detailed in the relevant drawings, with special emphasis made of the following points;

• All work shall be undertaken in strict accordance with the related specifications detailed under this project.


• The torque value applied when tightening all bolts shall be in strict accordance with the manufacturer’s recommendations and proof of this application submitted to the Project Engineer and/or Clerk of Works appointed to this project.

• Where any copper/aluminium connections are employed in the scope of the project, care must be taken to ensure the correct bi-metallic components are utilized.

• Strict adherence to the mandatory safety clearances (electrical, working, etc.) as determined by the latest edition of the OH&S Act, shall be enforced throughout.

All droppers and stringers must be installed according to the drawings. The natural curve of the conductor must be used at all times. No excessive stress shall be permitted on the equipment. Substation phasing is to be done as per station electric diagram. Post Insulators are to be aligned by using stainless steel shims.

1.5.7 TUBULAR BUSBARS Centipede conductor shall be laid in each of the tubes. The conductor must be ⅔ the length of the tube it is laid in. The end of the conductor must be secured to a tube conductor end cap. If any tube needs to be cut it may only be cut with a pipe cutter. Burs inside the pipe must be cleaned out after the tube has been cut to allow for the installation of the end cap.

1.5.8 CLAMPS AND LUGS (FOR CONDUCTOR) All clamps and acrylic covers are to be purchased from ELB McWade Electrical only. The clamps must be in accordance with the Eskom specifications. Tel.: (011) 316 2262 Clamps and lugs crimped as per manufacturer’s specification. Conductor must be clean, then greased with non-oxide grease prior to installation of clamp. Bolted clamps are to be torqued as specified on section drawings. All lugs to have heat shrink covering of 70mm. All 11/22kV transformer connections must be taped, including the 22/11kV transformer surge arrestor connections. First BICC compound is to be used to fill all the cavities of the clamp and to be formed before the tape is applied. Apply 2 layers of 3M 23 electrical tape and 2 layers of 3M Super 33+ tape to the clamp.

1.5.9 BOLTS All bolts supplied are to be set screws hot dip galvanized or stainless steel. Rawl bolts and hook bolts shall be galvanized. All bolts to have 2 washers and 1 nut. No damage to galvanizing will be accepted.

1.5.10 DOGBOX BREAKERS For dog box breakers M10 x 35mm long stainless steel set screws (with one nut and 2 washers per set screw) are to be supplied for the fixing of the support lacings and for fixing the breaker to the support. 32 set screws will be required per support and breaker installation.

1.5.11 BREAKERS AND LINE TERMINATIONS The drilling of the SPC clamps used for line terminations and breakers is to line up with the line flag and the breaker connection plate. A M12 x 65mm stainless steel bolt is to be used for the breaker application. A M16 x 50mm galvanized bolt is to be used for the line termination connection.

1.5.12 LABELS For equipment & busbar labels, 2 x M10 x 35mm long stainless steel set screws with one nut and 2 washers per set screw are to be supplied for the installation.

1.5.13 PANEL BOLTS When protection panels are secured to channels in the floor, bolts and “spring nuts” shall be used.


1.5.14 PALISADE FENCING All fencing shall be done as per the Standard Eskom Drawings D-DT-5237 sheets 1 & 2 and the fencing layout drawing. The Clerk of Works to give benchmark level when there is a difference in level of the fence. The panels to be used are to be calculated using the fencing layout drawing. The distance of closing panels (i.e. the last panel on each side) are to be measured once all other posts are in position and this measurement is to be used to manufacture the closing panel. Clerk of Works is to approve the proposal before the panels are manufactured. The fencing drawings are not to be modified in any way, unless approval is given by the Project Engineer. The pales to be used must be the “classic palisade” D section with countersunk bolts and shear nuts. Note : Special care should be taken when measuring the panel at the entrance to the sub adjacent to the runway and the lower level of the 22kV section of the yard. The steep incline will need special panels to connect the lower and upper level of the yard palisade fence.

1.5.15 2.4M STEEL POST MESH FENCE

N/A

1.5.16 LABELS AND SIGNS Install the following signs per gate (a gate with two panels is classified as one gate), sign ABC, sign DE, sign F and sign G. Install sign ABC on the first panel at each corner face of the fence and then at intervals not exceeding 20m along the fence. The word sum used in the BOQ is inclusive of all danger signs.

1.5.17 BRACKETS Palisade fencing, the signs are to be installed using label brackets as indicated on D-EC-1949. Mesh Fencing, the signs are to be installed using “A Grade Galvanized Binding Wire” on the corners of the labels or as needed to ensure that the label is well secured to the mesh.

1.5.18 TEMPORARY FENCE Note that while fencing work is being carried out, at no point is the substation perimeter to be left open and unattended. A temporary fence must be installed as per the following details: Install a 2,4m high fence using wooden posts to which 1.8m diamond mesh with a mesh size of 50mm x 50mm must be secured. 3 x strands of draw wire must be installed to secure the mesh to the posts and an additional 4 strands of barbed wire evenly spaced must be installed above the mesh. Top strand of barbed wire must be 50mm from top of posts. The fencing post spacing shall not exceed 4m intervals. The fence must be connected to the main earthmat as detailed in the Earthing Standard D-DT-5240. Install the applicable danger labels on the fence. The mesh must be earthed using 10mm round copper laced into mesh from top to bottom. An earth must be installed at each end of the fence and at 20mm intervals in between. All gates shall be earthed using flexible earth leads as per standard.


1.5.19 BRASS PRONGS A nut is to be removed from the bushing of the equipment identified in the scope of works, which needs prongs. The inner thread of the nut is to be used to determine the inner thread of the brass prongs. Prongs are to be tinned. HV transformers: the prongs are to be 26mm diameter x 110mm long. The internal thread of the prongs is to be 75mm in length. MV transformers: the prongs are to be 38mm diameter x 110mm long. The internal thread of the prongs is to be 75mm in length. Prongs for non-standard isolators are be 26mm diameter, 200mm in length of which 90mm to be turned down to 18mm diameter with a 45˚ chamfer. Note: No tapping is required for this prong.

1.5.20 YARD LIGHTS Yard lights are to be installed in the direction as indicated on the layout drawings. Supplier: Beka (PTY) LTD Tel: 043 726 0493 Product: BEKABEAM 250W HPS/T – WIDE BEAM C/W LAMP Or Supplier: Siyazama Suppliers Tel: Craig Heath 072 547 4858 Product: Zumtobel PRL 250 HPS/Wide beam Or Supplier: Genlux Lighting Tel: Greg Bower 031 569 4847/8 Product: Odyssey Series Part No. 22024

1.5.21 SHARK NETTING Shark netting is to be in accordance to the specification contained on D-DT-6103.

1.5.22 SWITCHGEAR RACK-OUT PLATE N/A

1.5.23 INDOOR SWITCHGEAR – EARTHING PANEL COVER N/A

1.5.24 LABELS Labels to be supplied are to be obtained from an Eskom approved supplier. The label schedule defines equipment labels required. The rate for Isolator labels shall include the non standard padlock and a key tag. The key tag shall be 100 x 25 and shall include both the “label designation” and “label description”. The station electric drawing must be forwarded to an approved label manufacturer who will design the mimic panel and key panel backing.

1.5.25 MIMIC PANEL The mimic panel will be sized by the manufacturer according to the amount of equipment within the substation [station electric] Max sheet size A1. The mimic panel shall include 12mm diameter magnetic buttons [1 of each colour per isolator] “Green” for open, “Red” for closed and “White with E” for earthed. The colours shall be as follows 132kV

Blue 132kV lines, busbars and equipment Red 66kV lines, busbars and equipment

Yellow 22kV lines, busbars and equipment

1.5.26 KEY PANEL A lockable wooden framed key panel is required which shall have a station electric layout similar to mimic panel mounted on the 10mm wooden backboard. The key panel shall be


75mm deep and will be complete with a 4mm glass door panel. The equipment detailed on the station electric will determine the physical size of the key panel. A brass cup hook must be fitted at each isolator position from which the non standard keys will be hung.

1.5.27 NON STANDARD PADLOCK A non standard padlock is required for all isolators installed as part of the project and shall be 50mm brass with either an 8mm brass or stainless steel shank complete with 3 keys.

1.5.28 SUBSTATION LINK STICK The link stick consists of the following sections;

• Section 1 4ft – part 5467-4 • Base section 4ft – part 552-4 • Operating head + adaptor – Part 363-179-204L • Bag for a 2 section link stick

1.6 Pricing specification

1.6.1 FOUNDATIONS When the installation of a foundation is priced, include the following as part of the price: (a) Excavation volume as per the foundation drawing – allowance should be made for over brake (b) Concrete volume as per the foundation drawing (c) Shuttering required as per the foundation drawing (d) Holding down bolts and the installation of it with a template (e) Connection of the flat copper to the holding down bolts, as well as the trenching required

to the main earthmat and the connection at that point.

1.6.2 EQUIPMENT For all equipment that is installed by Eskom Distribution the contractor, must supply the bolts, washers, bevelled washers and nuts of the correct size to secure the equipment to the steelwork.

1.6.3 SPC, STP, KCP, P and post insulator mounted t ubular busbar clamps Supply the bolts, nuts and washers required when the above mentioned clamps are installed.

1.6.4 PROTECTION CABLES & PANELS When pricing the installation of protection LV cables, include the removal and the reinstallation of all trench covers on route. The excavation, back fill and compaction of the sections of cable between the trench and the equipment is measured separately and is classified as soft and pickable. Where new panels are installed a 50 x 50 x 5 angle iron the length of the panel must be bolted to the back of the panel to support the chequer plate covers over the cable trenches. The paint finish will be a layer of undercoat [red oxide], and the final layer must be battleship grey.

1.6.5 EQUIPMENT LABELS The rate shall include the bolts required to connect the label to the equipment steelwork.

1.6.6 DISPOSAL OF WASTE Waste shall include spoil materials, decommissioned concrete, equipment packaging (Primary and Secondary), cable armouring and PVC sheathing from protection cables, etc. Rate to include provision of separate waste bins for PVC, Aluminium, Copper and general waste.


1.6.7 AIR CONDITIONING UNIT The air conditioner must be a wall mount 20 - 36 000 BTU split unit. The unit must be able to heat and cool. In case of a power failure the unit must restart when the power is restored. It must have a remote control that is hard wired to the unit. Allow for an external input to switch the unit on.

1.6.8 KERBING AND FENCING The rate for the installation of kerbing and fencing must include all the excavations required.

1.6.9 TRENCHING For pricing purposes, a trench of 1000mm x 400mm has been assumed. Compaction shall be as per 1.3.2 COMPACTION for sub-grade requirements.

1.6.10 PAVING The price for paving must include all preparation work as well all material needed.

1.6.11 REMOVAL OF EXCESS SOIL Excess soil which results from any activity requiring excavation is to be removed from the substation site and disposed of within Eskom’s boundary which will not exceed 100m from the substation. The excess material is to be flattened as per the existing area contours. The cost for the removal of the soil is to be included in the relevant activity requiring excavation.

1.7 General

All quantities in the bill of quantities are provisional. Quantities must be verified on site with the Project Manager before invoices are submitted. The contractor must familiarize himself/herself with the scope of works, drawings and the Bill of Quantities [BOQ]. Material supplied by contractor to be checked and approved by Clerk of Works prior to installation/erection. Rubble is to be disposed of at the nearest municipal dump site.

1.8 Quality Control

The latest revision of specification SCSASAAQ1, ‘Quality checking of Distribution Substation Construction before handing over for Commercial Operation’ shall be applicable to this project and must be completed in full by the Clerk of Works and returned to the Project Engineer with all the “as - built” documentation. Critical to the quality control process involved in the construction of this project are the various hold points, which are to be observed by the contractor(s) involved and enforced accordingly. Furthermore, the contractor shall implement his own quality check system throughout the duration of this project. The contractor shall provide regular feedback on all aspects of quality control on the site, which shall constitute a pre-requisite to the final hand-over / take-over stage of the project. The contractor shall ensure that all equipment to site is received by a competent person (Materials Receiving Clerk / Store man) who will ensure that all material is in good condition when received. A complete detailed inventory of all material is to be kept and must be available for inspection at any time by the Project Manager. Equipment damaged in transit or during construction, must be replaced / repaired at the Project Engineers / Clerk of Work’s discretion and any costs incurred shall be for the contractor’s account. The following safety clearances shall be strictly adhered to for all installed equipment and the associated conductors connected to such equipment;

System Voltage (Un) kV

Min. Electrical Clearances (mm) Min. Working Cleara nces (m) Ph - E Ph - Ph Vertical Horizontal

6.6 150 200 2.6 1.2 11 200 270 2.7 1.3


22 320 430 2.8 1.4 33 430 580 2.9 1.5 88 840 1150 3.3 1.9 88* 1000* 1350* 3.5* 2.1* 132 1200 1650 3.7 2.3

* Indicates values for full insulation at 88kV and are only to be used if the system is not effectively earthed

1.9 Project Risk analysis

Refer to Annexure 1

1.10 Safety specification

Refer to Annexure 2

1.11 As-built information

The “as-built” drawings and associated information form a vital part of this project. Consequently this project will not be considered complete until the “as-built” package complete with all the associated civil drawings have been submitted via the Project Manager to the Project Engineer involved with this project.


ANNEXURE 1

PROJECT RISK ANALYSIS

Project: Qunu SS Refurbishment PE (1): M Stoltz (Aurecon)

Portion of route affected: Analysis No: Date: Final Rating =

42 Risk Rating

Effect on Cost

Effect on Time

Proposed Action Plan

0 1 2 3 Risk Factors Description

Zero Low Med High

ENVIRONMENTAL RISKS (to be identified by Environmentalist and/or Survey or) Weather Rainfall X Construction to be scheduled out of rainy

season. Winds X Contractor to be aware of weather patterns. Heat Stroke X Snow / Hail X Floods X Fire X Agricultural Activity Cultivated Lands X Irrigation Equipment X Maize Crops (young, mature)

X

Sugarcane (young, mature)

X

Other Crops (veg,) X Livestock X All areas where work is taking place to be

fenced off and secured. Contractor to prevent any attraction of livestock to the site.

Tree stumps – logs X Trees - young / old X Natural Features Bush X Indigenous trees X Grasslands (tall grass)

X

Grasslands (short grass)

X

Wetlands X Boulders X Dongas X Dams X Streams / Water Furrows

X

River Crossings X Fauna and Flora Bird Interaction X Dogs X Game X Snakes X Wild Animals (lions,) X


Human Aspects Houses - Normal / Informal

X

Local Population X Schools / Clinics X Archaeological Sites X Access for Vehicles X ENGINEERING RISKS (to be identified by Surveyor, Project Engineer and Construction Supervisor) Legal access to site X Statutory Approvals X Incorrect survey pegs

X

Quality of drawings X Materials delivery delay

X

Quality of materials delivered

X COW and contractor to inspect all materials received. NCR to be issued for poor quality.

Incorrect materials delivered

X PM to ensure dispatch requests are correctly filled out.

Vandalism of materials

X

Protection of site & materials

X

Use of appropriate equipment

X

Machinery failure X Existing cables X All existing cable routes to be clearly marked

prior to excavations. Induction from other power lines

X

Proximity to other power lines

X Safety clearances to be adhered to at all times. Where required work is to be carried out under direct supervision.

Telkom lines X Water pipes X Main / farm roads X Motor vehicles / traffic

X

Rail line crossings X Damaged/rusted pylons

X Structures to be inspected visually prior to climbing. If necessary tests to be carried out to determine structure integrity.

Damaged/rusted hardware

X Care to be taken when dismantling old hardware. Area underneath hardware to be clear of personnel.

Damaged/rotten poles

X Structures to be inspected visually prior to climbing. If necessary tests to be carried out to determine structure integrity.

Damaged conductors X Care to be taken when dismantling old hardware. Area underneath conductor to be clear of personnel.

Personnel skill level X Contractor to appoint appropriately qualified and experienced supervisors to the project. CV’s can be requested to verify skill level.

Correct method application

X

OTHER RISKS


Hi-jacking X Theft X Communications – radio

X

Communications – telephone

X

Risk scoring method: If risks are identified then the maximum score = 60. When all the scores are added up on a specific project and the total = 45, then the project is considered to be in a “high risk / sensitive area”. If however the total score is only 25, then the project is considered to be in a “low risk / non-sensitive area”.


ANNEXURE 2

SAFETY SPECIFICATION

Project: Qunu Substation Refurbishment Contractor: Contract period: Client: Eskom Distribution (Southern Region) Date: Rev:

This document must be read in conjunction with the Detailed Specification and Project Risk Analysis (Annexure 1). This document must also be communicated to all relevant construction staff and displayed in appropriate positions at the construction site, the site office and the associated staff accommodation facilities. In terms of the Construction Regulations forming part of the Occupational Health and Safety Act, the contractor is sensitized to the following requirements;

1. Within one week of the contract being awarded, the contractor must submit a certificate of good standing with the Workmen’s Compensation Commission.

2. Within one week of the contract being awarded, the contractor must also submit an Occupational Health and Safety Plan to the client for approval, which amongst others, must deal with the mitigation of the anticipated project specific onerous site conditions that are likely to be encountered.

The following activities have been identified as Potential Risks and / or pertaining to the Health and Safety of the people employed to work on the specified site and / or to people in general in close proximity to the work site.

3.1 Excavations 3.2 Working at Elevated Levels 3.3 Construction Vehicles and Mobile Plant 3.4 Housekeeping on Construction Sites 3.5 Fire Precautions on Construction Sites 3.6 Construction welfare facilities

3.1 EXCAVATIONS The scope of work detailed under this project, requires the contractor as part of the contract, to undertake certain excavations that are more than 1 metre in depth. The lattice steel column foundations and the excavation of the oil containment tank are two examples of such a requirement. The contractor’s employees, as part of the contract, will more than likely also be required to work with certain mechanical excavation equipment that has the potential to inflict bodily injury. There is also likely to be excessive noise and dust present during the excavation process. The Contractor must ensure;

• That the necessary safety precautions regarding excavations deeper than 1 metre are strictly adhered, ie. Adequately shored and barricaded. The contractor is to ensure that these excavations are backfilled as soon as the concrete has cured and the requisite strengths have been achieved.


• That all excavation work is carried out under the supervision of a competent person who has been appointed in writing.

• That those employees working at, or in close proximity to such activity, must be supplied with suitable and effective dust and hearing protection.

3.2 WORKING AT ELEVATED LEVELS In terms of the contract, the contractor will be required to work at elevated heights. Examples of such activity include that associated with the construction of the substation building, steel lattice columns/beams, equipment support steelwork, conductor stringing, lighting/lightning masts, etc. The Contractor must ensure;

• All work undertaken above ground level will be supervised by a competent person appointed in writing.

• All applicable staff will be issued and satisfactorily trained in the use of a FAS (Fall Arrest System) to be worn and applied for all related work activity requiring the use of such a system.

• That all personnel working on site are equipped with and wear the necessary protective equipment and clothing, eg. safety helmet & boots, gloves, overalls, etc.

• No work will be performed at ground level, directly beneath workmen engaged in work at elevated levels.

• All equipment used in conjunction with, or to support that being undertaken at elevated levels, shall be inspected prior to its use, to ensure all is in good working order and in a serviceable condition to perform the function for which it has been designed to do.

3.3 CONSTRUCTION VEHICLES AND MOBILE PLANT During the construction phase of the substation, various equipment and mobile plant will be employed and described as, but not limited to: all terrain vehicles, vehicle mounted cranes, hole boring machine, compressor, tractor back-hoe, compaction roller, dumper, hydraulic crimpers, concrete mixer, hydraulic winches, etc. The Contractor must ensure;

• The use of construction equipment and mobile plant will be restricted for the use of only trained and authorized operators and will be supervised by a competent person appointed in writing.

• Are regularly maintained and in good working order. • Inspected daily prior to use by a competent and authorized persons. • All construction vehicles shall comply with the requirements of the Provincial

Administration Road Ordinance and those stipulated in the Road Traffic Act. • All mobile plant shall conform to the Occupational, Health and Safety Act (85 of

1993). • The construction site is arranged and managed, to ensure that as far as is

reasonably possible and practicable, all pedestrians and vehicles can move and work in a safe environment without risk to personnel or equipment on the construction site.

3.4 HOUSE KEEPING ON CONSTRUCTION SITE Throughout the duration of the construction activity at the applicable substation site, all practicable measures shall be employed to ensure good housekeeping practices are adopted. These activities will be monitored and maintained by a competent person appointed in writing


The Contractor must ensure;

• Suitable housekeeping methods are continuously being implemented on the site, including but not limited to, provision for the correct storage of all materials and equipment, the regular removal of scrap, waste and debris at appropriate intervals.

• Environmental policies will be strictly adhered to for the duration of the project. • Adequate, safe and secure storage areas shall be established, demarcated,

maintained and controlled accordingly. 3.4 FIRE PRECAUTIONS ON CONSTRUCTION SITE Throughout the duration of the construction activity at the applicable substation site, suitable precautionary measures shall be implemented to ensure the risk of a fire and/or fire hazard occurring is prevented. These measures shall be enforced by a competent person appointed in writing. The Contractor must ensure;

• All appropriate measures are taken to avoid the risks of fire. • No open fires shall be permitted on the construction site whatsoever. • Suitable and sufficient fire extinguishing equipment shall be available on site at all

times. • A sufficient number of site employees are trained in the use of firefighting

equipment. • All emergency related procedures are displayed at the construction and

accommodation sites and all applicable personnel are aware of these. • All relevant emergency appointments (fire wardens, evacuation officials, etc.) are

completed in writing and displayed accordingly. 3.5 CONSTRUCTION WELFARE FACILITIES During the construction phase of the substation project, Eskom’s construction staff and associated employees will be housed in accordance with the relevant policies and procedures governing this practice for the duration of the project. These facilities will be inspected and maintained by a competent person appointed in writing. The Contractor must ensure;

• Suitable and habitable accommodation, in accordance with all related policies and procedures governing this issue, shall be provided for all relevant construction staff.

• No accommodation facilities need be provided for the locally employed contract workers, ie. casual labour.

• Cooking, washing and eating facilities shall be provided for all relevant construction staff and these facilities cleaned daily to ensure compliance with the Occupational Health and Safety Act.

• Only approved cleaning materials shall be issued for the cleaning of these facilities. • Proper seating / eating furniture shall be provided in each eating area. • Adequate transport shall be made available to transport employees to and from their

home bases, during those periods when construction staff are ‘off site’. • Chemical toilets shall be provided and serviced to ensure same comply with the

requirements of the Occupational, Health and Safety Act.

VOLUME 3 DETAIL DESIGN - etenders.gov.za Rev3 201701... · Extend Qunu SS to be equipped with 2 x...

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