Ankerlig Additional Storage Tanks

Ankerlig Power Station
Specification No.
Employers Works Information Storage Tank Specification for Diesel Fuel Oil and Fire Water
Rev 0
December 2011
Page 1 of 48
Specification No.
File Reference:
Client :
Project Title:
Additional Diesel Storage
Report Title:
Additional Storage Tank Specification for Diesel Fuel Oil and Fire water
REV. NO.:
Volume:
1 of 1
PRODUCED:
Leonard Calana Tinus Keyser
DATE: 6 December 2011
CHECKED:
Phil Khumalo Mjongi Mdemka Paul Loots Pamela Mrubata Zahir Kapier Nkahle Sesiu Lynn Allies Riaan Mouton Saleigh Williams
APPROVED: TITLE:
Rodney Booth Plant Manager
Latest Revision Summary:
COPYRIGHT ESKOM HOLDINGS ALL RIGHTS RESERVED, NO PART OF THIS WORK MAY BE MODIFIED OR REPRODUCED OR COPIES IN ANY FORM OR BY ANY MEANS - GRAPHIC, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING, RECORDING, TAPING OR INFORMATION AND RETRIEVAL SYSTEM, OR USED FOR ANY PURPOSE OTHER THAN ITS DESIGNATED PURPOSE, WITHOUT THE WRITTEN PERMISSION OF ESKOM HOLDINGS
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Specification No.
TABLE OF CONTENTS Page No.
1.1.
GENERAL REQUIREMENTS .................................................................................6
1.1.1 Scope.................................................................................................................................................. 6 1.1.1.1 The Development......................................................................................................................... 6 1.1.1.2 Permits and Licenses .................................................................................................................. 6 1.1.1.3 Scope of the Works...................................................................................................................... 6 1.1.1.4 Exclusions .................................................................................................................................... 6 1.1.2 Site Conditions Access and Contractors Area ............................................................................. 7 1.1.2.1 Security ........................................................................................................................................ 7 1.1.2.2 Contractors Compound/Lay-down ............................................................................................... 7 1.1.2.3 Car Parking .................................................................................................................................. 7 1.1.2.4 Roads ........................................................................................................................................... 7 1.1.2.5 Co-operation with Other Site Service Providers/Good Neighbours Policy .................................. 7 1.1.2.6 Site Cleanliness ........................................................................................................................... 8 1.1.2.7 Working Hours ............................................................................................................................. 8 1.1.2.8 Industrial Relations ...................................................................................................................... 8 1.1.2.9 First Aid ........................................................................................................................................ 8 1.1.2.10 Manner of Execution - Personnel ................................................................................................ 8 1.1.2.11 Contractor's Representatives and Personnel .............................................................................. 9 1.1.3 Statutory Requirements, Codes, Building Regulations ................................................................ 9
1.1.4 Project Management ......................................................................................................................... 9 1.1.4.1 General ........................................................................................................................................ 9 1.1.4.2 Contractors Representative ...................................................................................................... 10 1.1.4.3 Competence of Welders and other Personnel ........................................................................... 10 1.1.4.4 Welders and Welders Qualification - General ........................................................................... 10 1.1.4.5 Welders Test ............................................................................................................................. 11 1.1.4.6 Programming ............................................................................................................................. 11 1.1.4.7 Progress Reports ....................................................................................................................... 11 1.1.4.8 Progress Meetings ..................................................................................................................... 11 1.1.4.9 Project Documentation .............................................................................................................. 12 1.1.4.10 Drawings .................................................................................................................................... 12 1.1.4.11 Calculations ............................................................................................................................... 13 1.1.4.12 Manuals ..................................................................................................................................... 14 1.1.4.13 Plant Identification System ........................................................................................................ 15 1.1.4.14 Procedures ................................................................................................................................. 16 1.1.4.15 Inspection and Tests .................................................................................................................. 17 1.1.5 Site Services .................................................................................................................................... 18 1.1.5.1 General ...................................................................................................................................... 18 1.1.5.2 Water Supply ............................................................................................................................. 19 1.1.5.3 Telephone/Fax ........................................................................................................................... 19 1.1.5.4 Power Supply ............................................................................................................................. 19 1.1.5.5 Sewage System ......................................................................................................................... 19 1.1.5.6 Washing and Sanitary Facilities ................................................................................................. 19 1.1.5.7 Fire Fighting ............................................................................................................................... 19 Page 3 of 48
Ankerlig Power Station 1.1.5.8
Specification No.
Personal Protection Equipment ................................................................................................. 19
1.1.6 Quality Assurance ........................................................................................................................... 20 1.1.6.1 General ...................................................................................................................................... 20 1.1.6.2 Quality Assurance, Concept and Control .................................................................................. 20 1.1.6.3 Quality Assurance Manual (QAM) ............................................................................................. 20 1.1.6.4 Works (Manufacturers Facilities) Quality Assurance Programme (WQAP) .............................. 21 1.1.6.5 Site Quality Assurance Programme (SQAP) ............................................................................. 21 1.1.6.6 Project Specific Quality Plan (PSQP) ........................................................................................ 22 1.1.6.7 Quality Control Records/Manual ................................................................................................ 23 1.1.6.8 Monitoring by the Employer ....................................................................................................... 23 1.1.6.9 Site ............................................................................................................................................. 24 1.1.7 Safety................................................................................................................................................ 24 1.1.7.1 Contractors Obligations ............................................................................................................ 24
1.2.
1.2.1
TECHNICAL REQUIREMENTS ............................................................................ 29

Metrological Site Conditions ......................................................................................................... 29
1.2.2 Working Arrangements .................................................................................................................. 29 1.2.2.1 Planning of Work........................................................................................................................ 29 1.2.2.2 Protection of the shell during erection ....................................................................................... 29 1.2.3 Storage Tanks ................................................................................................................................. 29 1.2.3.1 Terminal Points .......................................................................................................................... 29 1.2.3.2 Design Parameters .................................................................................................................... 29 1.2.4 Details of Tanks and Accessories Lots 1 to 2 .............................................................................. 30 4.1.1.1 General ...................................................................................................................................... 30 4.1.1.2 Operational philosophy of Diesel Fuel Oil tanks ........................................................................ 30 1.2.4.1 General ...................................................................................................................................... 31 1.2.4.2 Design Standards ...................................................................................................................... 31 1.2.4.3 Tank Drainage ........................................................................................................................... 31 1.2.4.4 Nozzle Details and Fittings ........................................................................................................ 31 1.2.4.5 Materials .................................................................................................................................... 31 1.2.4.6 Instrumentation .......................................................................................................................... 31 1.2.5 Details of Tank and Accessories Lot 3 ......................................................................................... 34
1.2.6 Corrosion Protection ...................................................................................................................... 36 1.2.6.1 Exterior Paint Protection System ............................................................................................... 36 1.2.6.2 Underside of Tank Floor-plates Paint Protection System ...................................................... 3637 1.2.6.3 Interior Paint Protection System ................................................................................................ 37 1.2.7 Cleanliness, Preparation, Painting, Finishing and Repairs of Painted Surfaces ..................... 37 1.2.7.1 Cleanliness of the System: Treatment of Internal Surfaces ...................................................... 37 1.2.7.2 Protection, Painting, Finishing and Packing .............................................................................. 37 1.2.7.3 Surface Preparation and Conditions for Painting ...................................................................... 37 1.2.7.4 External Tank Painting and Under-floor Plates ......................................................................... 37 1.2.7.5 Internal Tank Painting ............................................................................................................ 3738 1.2.7.6 Priming Coats Shop Priming Coat ...................................................................................... 3738 1.2.7.7 Post Welding Surface Treatment and Priming .......................................................................... 38 1.2.7.8 Repair of Damaged Paint-work.................................................................................................. 38 Page 4 of 48
Ankerlig Power Station 1.2.7.9 1.2.7.10 1.2.7.11 1.2.8 1.2.9
Specification No.
Control of Paint Thickness ......................................................................................................... 38 Areas for Special Attention .................................................................................................... 3839 Compatibility of Paints ............................................................................................................... 39
Pipework .......................................................................................................................................... 39 Tank Labelling ................................................................................................................................. 39
1.2.10 Civil Requirements .......................................................................................................................... 39 1.2.10.1 Materials for Civil Works ............................................................................................................ 39 1.2.10.2 Information for Civil Works ......................................................................................................... 39 1.2.11 Final Information to be Supplied before Contract Completion .................................................. 40
1.3.
1.3.1
APPENDICES ....................................................................................................... 41
APPENDIX A CODES AND STANDARDS ................................................................................... 42
1.3.2 ................................................................................................................................................................. 42 1.3.3 1.3.4 1.3.5 1.3.6 APPENDIX B ABBREVIATION LIST ............................................................................................ 43 APPENDIX C SAFETY, HEALTH AND ENVIRONMENTAL ........................................................ 45 APPENDIX D - CORROSION PROTECTION .................................................................................. 47 APPENDIX E - DRAWINGS ............................................................................................................. 48
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Specification No.
1.1. General Requirements

1.1.1
1.1.1.1
Scope
The Development
Ankerlig Power Station is at Atlantis in the Western Cape Province. The project was constructed in two phases, namely Ankerlig 1 which is 600MWe capacity, 4 x 150MWe gas turbines installed in separate enclosures and Ankerlig 2 which is 750MWe capacity, 5 x 150MWe gas turbines installed in one Turbine hall enclosure. The gas turbines are Siemens SGT5-2000E model which are nominally 150MWe units. The gas turbines are installed in the form of open cycle and are known as OCGTs (Open Cycle Gas Turbines). Eskom generation has identified an urgent need for additional diesel storage tanks at Ankerlig due to required increased operation of the gas turbines. The gas turbines were originally installed to operate on Peaking generation, which is morning and evening peak with the load factor of 3 to 5%. The projected load factor for the gas turbines operations has gone up to 40% in some months and the existing diesel storage tanks will not meet with these projected load factors. This works information is concerned with the additional diesel storage tanks for Ankerlig Power Station. The additional diesel storage tanks will be considered by the Employer as an extension to the existing diesel storage system.
1.1.1.2
Permits and Licenses
The Employer is responsible for obtaining all the relevant permits and licenses associated with the development of the additional diesel storage tanks. The Contractor is responsible for obtaining all the relevant permits and licenses associated with the construction, installation and commissioning of the additional storage tanks contract for Ankerlig Power Station.
1.1.1.3
Scope of the Works
The scope of this contract is to carry out the process and mechanical design, manufacture, and supply, delivery, erection, testing, painting and corrosion protection, commissioning and handover of storage tanks at Ankerlig Power Station. Tanks are required for the storage of No 2 distillate fuel oil, and raw fire-fighting water. The scope will be in two lots as follows: Lot 1 two No 2 distillate fuel oil storage tanks at Atlantis. Lot 2 one fire water tank at Atlantis. Civil works including bunds
1.1.1.4
Exclusions
The following Activities are specifically excluded from the works: Off loading pumps only but not the connecting piping.
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Specification No.
1.1.2
1.1.2.1
Site Conditions Access and Contractors Area

Security
The Contractor shall conform to all Site security requirements. Furthermore the Contractor shall be responsible at all times for the security of his own personnel, equipment and materials and for the security of their operations within the Site extent.
1.1.2.2
Contractors Compound/Lay-down
A suitable Contractors Lay-down Area is made available to the Contractor. The Contractor shall be responsible for preparing, stoning, servicing and rendering secure such area of this lay-down area, which he deems necessary for his storage and accommodation requirements. The Contractor shall provide any covered storage accommodation and Site offices required for his materials equipment and workforce. The Contractor shall keep his area clean and tidy and shall remove all waste and surplus material daily. It is the responsibility of each Contractor to fence its own lay-down area as deemed necessary inside the Contractors lay-down Area. It is the responsibility of the Contractor to determine whether he requires security for his lay-down Area and provide if required. The Contractor shall, before commencing work, submit details of all buildings he proposes erecting in the Contractors lay-down Area and the Construction Site for storage, workshop and offices for the Project Managers approval. At the end of the Contract, the Contractor shall remove all sheds, offices, toilets, surplus materials etc., remove all temporary connections and leave the Site in a tidy and safe condition.
1.1.2.3
Car Parking
Car parking shall be provided. No car parking shall be permitted in other areas or on Public Roads. Construction vehicles are allowed on Site however a permit is required from the Project Manager. For offloading the Contractor shall be confined to its own lay-down area.
1.1.2.4
Roads
The Contractor shall ensure that existing roads are used with due regard to maintaining their current condition and any damage whatsoever caused by the Contractor shall be immediately repaired to the satisfaction of the Project Manager. The Contractor shall take adequate care to ensure no spillages occurring onto the public roads during transportation of materials to/from the Site. Any debris/spillages that occur on the public and Site roads shall be the responsibility of the Contractor and shall be immediately removed/cleaned up. With regard to prevention of any deposition of muck, dirt etc on roads, the Contractor shall make all provisions necessary for the cleaning of vehicles leaving the Site.
1.1.2.5
Co-operation with Other Site Service Providers/Good Neighbours Policy
1.1.2.5.1. General The Contractor shall arrange his operations in such a way as to avoid causing interference and to minimise disturbance to other staff and to the users of the Site and public roads. The Contractor shall ensure that the works carried out do not interfere with the operation of the Ankerlig Power Station except where such interference is deemed unavoidable and is approved by the Project Manager. Permits will be required for access to the existing Ankerlig 1&2 plants.
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Ankerlig Power Station 1.1.2.5.2. Other Service Providers
Specification No.
The Contractors attention is drawn to the fact that there shall be other service providers who will require access along routes which will be subject to construction activities. This will require cooperation with the Project Manager by all relevant parties to ensure that disruption to all contracts is minimised.
1.1.2.5.3. Good Neighbours The project has a good neighbours policy. This means that any inconvenience caused by the Site operations to people who work or live in the vicinity shall be minimised. The Contractor shall take all precautions to avoid the creation of noise, dust, noxious smells, offensive behaviour or other pollution on the Site. The Project Manager may at his discretion prohibit any activities, which breach the spirit of this intent.
1.1.2.6
Site Cleanliness
The Contractor shall at all times keep his work and storage areas clean and tidy and at regular intervals, which shall not exceed a week, shall remove all waste or surplus material and arrange and pay for disposal off Site. The Contractor shall provide adequate skip facilities around the Site for waste disposal. The Contractor shall safely clear the Site of temporary structures, surplus material, equipment, fuel, all liquids and erection equipment and tools on completion. Where the Contractor fails to meet these requirements, the Employer may remove materials from Site and charge resultant costs to the Contractor.
1.1.2.7
Working Hours
The Contractor shall comply with the working hours on Site unless otherwise agreed with the Project Manager. The working hours for the Site are between the following hours: 06.00 18.00 06:00 13:00 Monday to Friday Saturday
1.1.2.8
Industrial Relations
The Contractor shall comply with all local statutory and other labour laws and regulations pertaining to the Works.
1.1.2.9
First Aid
The Contractor complies with all statutory requirements in addition to the requirements of this Specification.
1.1.2.10
Manner of Execution - Personnel
During the erection of the Works, the Contractor (or Sub-Contractor) shall pay the wages for any local labour, skilled or unskilled, employed by him and shall comply with the working hours and holidays appropriate to the district and with the Basic Conditions of Employment Act.
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Ankerlig Power Station 1.1.2.11 Contractor's Representatives and Personnel
Specification No.
The Contractor shall appoint a Site Manager from the date of commencement of the Construction Work on the Site. The Site Manager shall be responsible for the organisation and co-ordination of the entire installation and shall be authorised to make binding arrangements. The Contractor should supply a full time safety representative. The Contractors Safety Representative is required to attend all safety meetings on Site. The Contractor shall provide on the Site adequate changing facilities for his workforce suitably equipped with lockers, changing facilities and toilets and shall provide for adequate attendance to maintain the facility.
1.1.3
Statutory Requirements, Codes, Building Regulations
The Contractor shall be required to assume full professional liabilities with regard to fulfilment of any Statutory Requirements. In this regard, the Contractor is advised to acquaint himself thoroughly with the local statutory regulations and requirements in the Republic of South Africa together with relevant data/undertakings contained in the approved documents. Codes and standards governing the design, construction, commissioning and testing of the Plant must be accepted by the Project Manager. The Plant and each individual portion thereof must comply with internationally accepted codes and standards. In case of conflict between international codes, standards or guidelines and the requirements specified in this Functional Specification, the more onerous specification takes precedence. As a minimum requirement the contractor shall comply with all legislation and mandatory codes and standards.
1.1.4
1.1.4.1
Project Management
General
Further to the NEC requirements the Contractor shall submit a Project Implementation Plan (PIP) for acceptance which shall not materially deviate from that submitted with the tender. Any deviations will be subject for acceptance by the Project Manager. The Contractor shall submit organisation charts to indicate the relationship of the project management team to the Contractors overall organisation and shall identify the person with overall responsibility, authority and control. The Contractor shall prepare a Project Management Manual setting forth the responsibilities and levels of authority within the Project Management Team and Contractors organisation chart. Names and curriculum vitae of other key personnel including designers shall be submitted to the Employer by the Contractor. It is a requirement that the key personnel, in particular, have good communication skills in the English language. Key personnel shall be appointed to the acceptance of the Project Manager. Any Contractor or sub-Contractor personnel deemed by the Project Manager to be incompetent, negligent or otherwise objectionable shall be removed from the jobsite or design/manufacturing phase immediately upon the request of the Project Manager. Key personnel shall not be replaced without the approval of the Project Manager. It shall be a requirement that key personnel of the Contractors Project Management Team provide continuity in the control of the Works until the end of the warranty period. Any Contractor or sub-Contractor personnel deemed by the Project Manager to be incompetent, negligent or otherwise objectionable shall be removed from the jobsite or design/manufacturing
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Specification No.
phase immediately upon the request of the Project Manager. Key personnel shall not be replaced without the acceptance of the Project Manager. It shall be a requirement that key personnel of the Contractors Project Management Team provide continuity in the control of the Works until the end of the warranty period. The Contractor shall prepare and implement a document management system, for receiving, distributing, and retaining project correspondence, design data, drawings, specifications, instruction/ data books, test reports, progress reports etc. Data books for each system shall contain the following: Complete set of as built drawings. All quality documents. Completed Quality Control Plans. All test results (including material mill certificates, welding maps, pump test curves, electrical equipment tests, etc.) All equipment specifications. Operating and maintenance manuals. The final master document shall be handed over to the Project Manager. The Contractor shall implement and keep up to date a configuration management plan (including KKS coding).
1.1.4.2
Contractors Representative
The Contractor shall appoint a person at the date of signing the Contract (The Contractors Representative) who will have full responsibility for the complete Works and act as a single point of contact in all matters on behalf of the Contractor. The Contractor's Representative shall be responsible for the organisation and co-ordination of the entire installation and for clarification of all pending installation questions with the Project Manager and the Contractor's Representative shall be authorised to make binding arrangements. The Contractor shall supply a full time safety representative who has responsibility for carrying out all safety tasks. The Contractors Safety Representative is required to attend all safety meetings on site.
1.1.4.3
Competence of Welders and other Personnel
The Contractor (or Sub-Contractor) shall employ, for execution of the Works, only personnel possessing a level of competence, skill and (where called for) qualification which is adequate for the tasks assigned to them. For welding operations each welder shall possess a valid certificate of competence as specified in the appropriate design or construction code. Before commencing any work on the Site, this certificate must be produced for inspection by the Employer. The Contractor shall have valid and current welder qualifications certificates appropriate for the welding to undertaken by each of the Contractors or subcontractors welders.
1.1.4.4
Welders and Welders Qualification - General
Welders employed on any work under the Contract, either at manufacturers facilities or on site, shall be proved to be competent to carry out the type and standard of welding required prior to commencing work. All welders shall be qualified in accordance with EN 287 or approved equivalent, international standard. Page 10 of 48
Specification No.
In the case of pressure parts and pressure part attachment welds, each approved welder shall have a unique identification number which shall be indicated on all welds made by him and on all permanent test records applicable to those welds including radiographs. All welders engaged on either shop or site welding shall be under the supervision of a competent welding engineer. The Contractor shall submit details of his control procedures for welding, heat treatment and non-destructive testing as part of the quality control procedures.
1.1.4.5
Welders Test
Sample welds shall be carried out on specimens of similar shape, thickness and chemical analysis to the material to be welded, and in a position which shall represent as far as possible the worst conditions under which actual welding will take place. The method of preparation of the test pieces, and the standards to be used in examination of them shall be according to the agreed Standard or Codes, or as may be agreed with the Employers Representative. All expenses in connection with welder's tests shall be borne by the Contractor. The range of approval shall cover all welds to be undertaken by the welders.
1.1.4.6
Programming
The Contractor shall appoint a fully experienced scheduler competent in the use of Primavera P5 to undertake all programming for the complete Works for the period of the contract. The scheduler will transfer to site and be located on site during the installation and commissioning of the plant. Programming shall be in accordance with Clause 31 of the NEC Engineering and Construction Contract. The Contractor shall furnish a detailed programme and critical path analysis indicating each separate operation in the works. The Contractors programme and critical path analysis shall be processed at least monthly throughout the Contract. In addition, the Contractor shall furnish to the Project Manager each week a detailed statement of the work he proposes to carry out each day of the following week.
1.1.4.7
Progress Reports
The Contractor shall be required to furnish progress reports in accordance with Clause 32 of the NEC Engineering and Construction Contract. In addition, the Contractor shall be required from time to time to estimate final and intermediate (e.g. delivery) dates. Relevant photographs of construction progress shall be included with the Project Report. The progress of the entire project will be controlled using a critical path analysis programme. The Contractor will be required to furnish weekly and monthly progress reports against approved programmes, in a format approved by the Project Manager.
1.1.4.8
Progress Meetings
The Contractor shall be required to have regular progress meetings at intervals to be agreed, but at a minimum of monthly with the Project Manager. During the design, engineering, procurement and manufacturing phases, progress and design review/clarification meetings shall be held with the Project Manager on an as needed basis, but as a minimum once a month. When construction / commissioning activities commence, progress meetings shall be held monthly on Site, supplemented by weekly (or as required) site meetings to review progress and measurements of site activities. The Contractor shall appoint an experienced planner to the Site from commencement of construction on Site for the duration of major construction work. Page 11 of 48
Specification No.
At any stage during the Contract special meetings may be arranged as necessary to resolve any technical or commercial issues. Each party shall pay their own travel and accommodation expenses for the meetings. It is the Contractors responsibility to organise Progress Meetings and to issue Minutes of Meeting.
1.1.4.9
Project Documentation
1.1.4.9.1. Submission of Project Documentation The Contractor shall provide within one (1) month from the Contract Date a complete time schedule for submission of all documentation including drawings, methodologies, design calculations, schematics, wiring tables/diagrams, manuals, procedures and any other information. It is an essential requirement that all documentation and any other information shall be submitted to the Project Manager at a specified date and in sufficient time for acceptance before proceeding with the relevant part of the work. In particular all drawings, operating philosophy, control philosophy, design philosophies and design calculations shall be submitted at regular intervals to ensure a steady flow of submissions. Acceptance may be delayed if large quantities of documentation are submitted at the one time. Acceptance by the Project Manager will not relieve the Contractor of his obligation to meet all the requirements of the Contract or relieve the Contractor of his responsibility for adequacy of design calculations and drawings and other documentation. All project documentation shall be transmitted electronically in addition to three hardcopies. If the Contractor provides drawings which are common to multiple units / systems / items of plant the Contractor shall put in place a programme to ensure that any differences are highlighted and documented on all relevant drawings (including as-built), procedures & instructions specific to each unit. Configuration management will be implemented to ensure that all documents are kept up to date and reflect the as-is and as-built status.
1.1.4.10
Drawings
1.1.4.10.1. Contract Drawings Three (3) hardcopies of all drawings plus one (1) electronic copy shall be submitted in sufficient time to permit comment and/or modifications being made without delaying the Contract Delivery and Completion Dates. For key drawings, the Project Manager reserves the right to request additional copies. Within one (1) month of Contract Date, the Contractor shall submit a detailed Master Drawing Schedule in EXCEL or other approved format, showing each drawing, including subcontractors drawings, and the date for submission of these drawings for acceptance by the Project Manager. Columns will be provided in this schedule for the following information: Date of submission to the Project Manager. Date on which Project Manager Comments are received. Dates of re-submission and further comments if applicable. Dates on which drawings issued for construction. Dates on which drawings subsequently revised. Date on which drawings issued in as-built form. Page 12 of 48
Specification No.
This Master Drawing Schedule shall be updated and submitted to the Project Manager for acceptance. A copy of the updated Master Drawing Schedule shall be included with the Progress Report. Following completion of construction of the tanks the Contractor shall subm it Asbuilt drawings for the Project Managers acceptance. The accepted drawings shall be duly stamped As-built.
1.1.4.10.2. Construction Drawings Construction drawings shall include fully dimensioned arrangement and detail drawings giving the design code, operational and design pressure and temperature and the ratings, scantlings and materials of all components. Weld details and applicable WPS shall be included and any specific construction and manufacturing procedures. All non destructive examination and hydrostatic testing requirements shall also be given.
1.1.4.10.3. Preparation and Format All drawings supplied under the Contract shall have titles and explanatory notes in English. In addition, English translations of any Standard, Specification or Document related to the design, production, inspection or testing of any part of the Works shall be supplied. The drawings shall be prepared in accordance with a recognised international or national standard and include a title block accepted by the Project Manager. For hard copies of drawings ISO A sizes shall be adhered to and except in special circumstances, sizes larger than A1 shall not be used. Drawings shall preferably be supplied in Microstation format and copies of all drawings shall be provided on CD-ROM or other suitable computer media.
1.1.4.11
Calculations
1.1.4.11.1. Submission of Calculations All design calculations shall be submitted to the Employer for information.
1.1.4.11.2. Presentation of Calculations Calculations must be comprehensive, coherent and suitably referenced to information sources and cross referenced within themselves. All calculations, other than computer printout, shall be on A4 size paper properly bound. Each book of calculations shall have a title page. The title page shall indicate clearly: Contractors name. Project name. Designers name. Checkers name. Contract number. Calculation title. Assumptions used for design purposes including reference to Basic Design Criteria Document.
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Ankerlig Power Station Codes and Standards used. Loadings used (where applicable). Date of Calculation. Calculation. Reference sources Manufacturers names and literature. Reference to the appropriate drawing. Technical specification section and paragraph number. Control register reference as applicable. Date of issue.
Specification No.
The title page shall also provide for the recording of any revisions (and dates) to the calculations. Calculations shall be in English and in SI units, clearly legible, preferably typed and bound in stiffbacked ring binders. Calculations which are not easily legible or which present difficulty in comprehension will not be accepted by the Project Manager and the Contractor shall be obliged to resubmit such calculations in legible/comprehensible form for acceptance by the Project Manager. The Contractor shall provide a master design schedule in Microsoft Excel format which will be updated on a monthly basis. It will have columns showing dates for submission by the Contractor and comments by the Project Manager as required in Sub-section 1.1.4.10 for Calculations. A copy of the updated Master Design Schedule shall be included with the Progress Report.
1.1.4.12
Manuals
The Contractor shall provide four (4) hardcopy sets of the manuals for each station to enable the Project Manager to comment and request changes as necessary. Copies of all Manuals shall also be provided on CD-ROM or other suitable computer media marked for review. The final version (as built) of all Operations and Maintenance (O&M) manuals shall be provided four (4) months after taking over of the plant, marked final version. In all cases, and irrespective of hard copies supplied, electronic copies of manuals are required in a Microsoft / .pdf format suitable for use with Eskoms user software standards. All manuals shall be divided by systems or sections and cross indexed as necessary.
The number of copies required is four (4).
The manuals are complete with: power station name and order number; content list; list of reference drawings; details of all components The manuals are submitted in loose-leaf binders to ISO format and normally A4 size. The use of oversize pages is kept to a minimum and does not exceed page height unfolded. Fixings are Page 14 of 48
Specification No.
preferably D ring and are of the snap close type. Post binders or other fixings are not acceptable. Binders do not exceed 80mm in overall thickness. The document identity appears on both the front cover and on the spine. Manuals are of good quality prepared by suitably experienced personnel and contain general arrangement drawings, installation drawings and instructions, operating and maintenance instructions for all components, detailed parts lists which are accompanied by exploded view type drawings clearly detailing the part and uniquely identifying it, technical descriptions of the plant and material and component parts, spare part ordering instructions and type test certificates. Any special instructions pertaining to storage of spare parts or to their shelf life are included in the manual. All drawings required for component location, dismantling, and re-assembly for maintenance is provided in the manual. All special tools required for maintaining and operating the plant and material are identified in a schedule and described in the manual. Manuals are produced such that a Synopsis is first presented, followed by a First Draft, then a preprint Proof and finally by the Approved Manual. The required documents are submitted for acceptance on the dates as shown in the key date schedule.
1.1.4.12.1. Design Manual This manual shall contain all the design calculations and all equipment and system data sheets and design criteria required under the Contract.
1.1.4.12.2. Construction Manual This shall include a comprehensive record of as built site construction tests and records. The manual(s) shall be compiled in separate parts to reflect the plant and services supplied.
1.1.4.12.3. Commissioning Manual This manual shall include all the records, certificates and test results arising from the agreed precommissioning and commissioning procedures carried out on site. The performance tests and guarantee test results shall also be included. There is a particular requirement that all commissioned plant/equipment values be recorded in this manual and subsequently incorporated into the final version of O&M manuals.
1.1.4.12.4. Quality Assurance Manual (QAM) Refer to section 1.1.6.3 in this document.
1.1.4.12.5. Quality Control Records/Manual Refer to section 1.1.6.7 in this document.
1.1.4.13
Plant Identification System
A common alphanumeric designation system for the codification of all items of plant, equipment and components shall be used for the whole power station. The coding system is based on the Kraftwerk Kennzeichen-System (KKS), as developed by the VGB (Germany) and adapted for Eskom. The Contractor shall be responsible for ensuring that he is fully familiar and compliant with the standards and concepts of the KKS system as applied by Eskom.
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Specification No.
The Contractor shall be responsible for the codification of all plant, equipment and components in his supply for which he is responsible in terms of engineering and design. The specific KKS-code of each item of plant, equipment, component, measuring points, junction box, cable, etc., shall appear on all documents, instruction manuals, schedules, drawings (i.e. flow diagrams, general arrangement, schematic diagrams, cable block diagrams, etc.) and labels for plant, equipment and components. A list of all KKS codes used by the Contractor shall be provided in accordance with Eskom standard documentation. The relevant KKS-code shall be included on the label according to the required Eskom standard format. The allocation of all codes shall be to Eskom approval. The Contractor shall ensure that the code is applied in a uniform and consistent way and that all codes allocated are unique.
1.1.4.14
Procedures
1.1.4.14.1. Weld Procedures, Specifications and Documentation For all pressure pipelines, containment vessels, and structural welded items, the Contractor shall submit to the Project Manager for comment, the following documents prior to commencement of welding: Welding Procedure Specification (WPS). Weld Procedure Approval Records (WPAR). Welder Qualification Records (WQR). Pre- and Post- Weld Heat Treatment where applicable. Inspection Schedule including Quality Assurance and Quality Control Requirements. Third party inspection authorities and / or authorised bodies. Non-destructive Examination and Testing Procedures. Standard Weld Repair Procedures. All welding procedures including those proposed in repair situations shall be qualified as required EN288 or approved equivalent and all qualified procedures shall be submitted to the Project Manager for acceptance prior to the commencement of any welding. Tube ends shall be prepared in accordance with an internationally recognised standard for welding tube to tube, tube to wall and tube to headers, etc. Inspection records will be stored on site and available in a coherent and traceable manner when required.
1.1.4.14.2. Welding Electrodes and Consumables Before any welding is commenced, the Contractor shall submit a list of all electrodes and consumables to be used, to the Project Manager for acceptance. In each case, the appropriate DIN, BS, ASTM or equivalent designation together with the proprietary brand name shall be given. Welding electrodes shall be suitably stored before use.
Page 16 of 48
Ankerlig Power Station 1.1.4.14.3. Site Welding
Specification No.
The Contractor shall be required to establish the procedures and conduct the tests, or provide the evidence required, according to the agreed Welding Code to qualify the procedures, for use with the agreed Construction Code and the welders for the application of the procedures.
1.1.4.14.4. Erection Procedures The Contractor shall submit four (4) sets of the erection procedures for each tank to the Employer for information so as to allow the Project Manager to comment one (1) month prior to the referenced erection commencing on Site.
1.1.4.14.5. Pre-Commissioning and Commissioning Procedures The Contractor shall prepare four (4) sets detailed testing and pre-commissioning procedures to cover the period from completion of erection to ready to start-up and all commissioning tests and procedures to be carried out to achieve readiness for performance testing. These procedures shall be submitted to the Project Manager two (2) months prior to commencement of the precommissioning.
1.1.4.14.6. Performance and Guarantee Tests Procedures The Contractor shall submit the performance and guarantee tests procedures to the Employer for comment, at a date to be agreed, but not less than two (2) months prior to start of commissioning.
1.1.4.15
Inspection and Tests
1.1.4.15.1. Materials All construction materials will be new and clean and will be free from rust and pitting and the cast numbers will be clearly marked. Material cast numbers will be checked for compliance with the material certificate and the requirements stipulated on the drawings. Manufacturers material certificates of chemical analysis and mechanical properties shall be submitted for all material used in the Works or as otherwise accepted by the Project Manager. Materials are to be accepted by the Project Manager. Where a test piece fails to comply with the relevant material specification or the material cast number indicates a material not compliant with the material stipulated on the drawings the Project Manager reserves the right to reject the whole of such material. Materials proposed for use are subject to the approval of the Project Manager. The Project Manager may reject the materials at his absolute discretion.
1.1.4.15.2. Inspection of Welding The extent of weld inspection, the final weld quality, and the method of examination shall be as stated in the agreed Standards or Codes. All welding inspection shall be performed by Welding Inspectors that are qualified to perform inspections. The Contractor shall maintain, both at the manufacturer facilities and on site, adequately indexed records of all welding, weld inspection and repairs which shall be available to the Project Manager, together with light box facilities and dark room for viewing of X-ray radiographs.
Page 17 of 48
Ankerlig Power Station 1.1.4.15.3. Weld Repairs
Specification No.
The Contractor shall immediately advise the Project Manager of any repair required on the Works. Where such repairs are found to be necessary by welding, dimensioned sketches of the excavated areas shall be prepared and the proposed repair procedures submitted for acceptance by the Project Manager before any repair is undertaken. In the case of weld cracking, the Project Manager shall require a full investigation to be made to establish the cause of cracking. No repair work or removal of the evidence shall be undertaken prior to acceptance of the repair procedures by the Project Manager. The cost of all such investigations and reports shall be wholly borne by the Contractor.
1.1.4.15.4. Non-Destructive Tests All welds shall be tested in accordance with the relevant standards accepted by the Project Manager. This is a minimum requirement and in no way limits the Contractors overall responsibility for quality of fabrication.
1.1.4.15.5. Pressure Tests The Contractor shall hydraulically test all parts subjected to internal pressure under normal or abnormal working conditions after satisfactory completion of the other non-destructive tests in accordance with the applicable codes. The Contractor shall be required to perform a Hydro-test and shall include all fittings and hoses for this purpose. Hydraulic test pressures quoted shall in all cases be the difference between internal and external pressures and in each test, the test pressure shall be maintained for sufficient duration to allow a thorough inspection of all seams, joints and connections; but in no case shall a test of less than that specified in the API650 standard. The Contractor will supply all equipment, suitably calibrated, to perform these tests. Water will be made available to the Contractor for the purpose of the hydro-test. The contractor shall demarcate and appropriately make safe the area surrounding the tank during hydraulic tests. A hydro-test procedure and programme will be submitted to the Project Manager for acceptance prior to a test being carried out.
1.1.4.15.6. Low Pressure Pneumatic Leak Testing The Contractor shall include for pneumatic testing of all reinforcement plates used.
1.1.4.15.7. Third Party Inspection The Contractor shall provide for a third party inspection of pressure systems. This inspection should include for the review of the design, welding and erection procedures and a review of the NDT results of the welds. The third party Inspection Company should provide certification that the work is complete, to their satisfaction and meets all statutory requirements.
1.1.5
1.1.5.1
Site Services
General
The Contractor shall provide all necessary services at the required locations.
Page 18 of 48
Ankerlig Power Station 1.1.5.2 Water Supply
Specification No.
The Employer will provide a construction water supply at a source within the Site boundary The Contractor shall be entirely responsible for providing his own water supplies in the Contractors Area. It is the responsibility of the Contractor to make an agreement with the Employer for the supply of water to the Contractors Area.
1.1.5.3
Telephone/Fax
The Contractor shall be entirely responsible for providing his telephone connection in the Contractors Site office area The Contractor shall bear all charges associated therewith including payments for the supply of services.
1.1.5.4
Power Supply
The Employer will provide a construction power supply to the site boundary. The Contractor shall be entirely responsible connecting to this source and routing the cables as required by the Project Manager. The Contractor shall indicate the extent of supply required. The Contractor shall bear all charges associated therewith including payments for the supply of services. All wiring and electrical work carried out by or on behalf of the Contractor shall conform to the Employer's regulations, be maintained in a proper condition, and be to the satisfaction of the Project Manager.
1.1.5.5
Sewage System
The Employer will provide appropriate connection to the sewerage system in the site area.
1.1.5.6
Washing and Sanitary Facilities
The Contractor will provide all provisions necessary for washing and sanitary facilities to conform to Statutory Health and Safety requirements.
1.1.5.7
Fire Fighting
The Contractor shall provide adequate fire fighting provisions for their construction area. Fire extinguishers shall be provided by the Contractor in the work areas and his staff shall be trained in their use. The Contractor shall comply with recommendations provided in NFPA 850 for fire protection during construction. The Contractor shall ensure that there is no interference by his employees or by his sub-Contractors with the ring main and equipment other than for use in fire fighting. He shall arrange that in all areas under his control the recommended type of fire extinguishers shall be properly identified by suitable markers and regularly serviced.
1.1.5.8
Personal Protection Equipment
Protective equipment of an appropriate type and standard shall be worn by all persons without exception while on site. Minimum shall include safety helmet and footwear, and, where necessary, ear protectors and eye protection glasses.
Page 19 of 48
Specification No.
1.1.6
1.1.6.1
Quality Assurance
General
The Contractor shall for all the Works to be performed have established and implement quality assurance arrangements which meet the requirements set out in the International Standard ISO 9001:2000 Quality Management System, which shall include, in a transparent manner, the quality assurance and quality control of its sub-contractors during all phases of the Contract, including, Design and Engineering, manufacturing, Site Construction, Erection, Commissioning and Start-up. The Contractor shall check all parts of the Works before dispatch from the manufacturing facilities to ensure that all materials, dimensions and tolerances are in accordance with certified drawings and mill certificates.
1.1.6.2
Quality Assurance, Concept and Control
This section provides the minimum requirements for establishing and implementing a quality assurance programme which is applied to all aspects of the work necessary for carrying out the Contract. The scope of this section extends to material parts, components, systems and services as a means of obtaining and sustaining the reliability of critical items, operating capacity and availability. If the Contractors programme does not cover the quality assurance requirements as indicated in this section then he must state, together with documentary evidence, the reason why the requirements do not apply. Acceptance of the Contractors quality assurance programme does not relieve the Contractors obligation to comply with the requirement of the Contract. If the programme is found to be ineffective or inadequate in providing for quality assurance or control, then the Project Manager reserves the right to request for necessary revisions of the programme. The Contractor is required to produce readily identifiable documentary evidence covering the extent and details of both his own and his subcontractors quality assurance sys tem. The documentary evidence should take the following form: Quality Assurance Manual (QAM) Works (Manufacturers Facility) Quality Assurance Programme (WQAP) Site Quality Assurance Programme (SQAP) Project Specific Quality Plan (PSQP) While acknowledging that the Contractor may combine the QAM, WQAP and SQAP as one document, it is a specific requirement of this Specification that these documents are prepared separately and submitted to the Project Manager.
1.1.6.3
Quality Assurance Manual (QAM)
The QAM shall be a general comprehensive document outlining the Contractor's basic organisation, policies and procedures. The information to be given in the QAM shall include but not be limited to: Quality policy Quality assurance programme Organisation structure showing inter-relationships Functional responsibilities and levels of authority Page 20 of 48
Ankerlig Power Station Lines of communication Customer relations Laboratory facilities Design review
Specification No.
1.1.6.4
Works (Manufacturers Facilities) Quality Assurance Programme (WQAP)
The WQAP shall detail the Contractor's quality assurance programme at Works applicable throughout all phases of Contract performance including design, procurement, manufacture, inspection and testing. It shall identify each of the programme elements to be designed, developed, executed and maintained by the Contractor for the purpose of ensuring that all supplies and services comply with this Specification including the Employers requirements. The information to be given in the WQAP shall include typically: Organisation and responsibility Design and document control Procurement control Control on sub-Contractors In-process quality control Welding quality control Heat treatment control Inspection and testing Control of non-conformances Corrective action Control of inspection, measuring and test equipment Handling, storage and delivery Records Quality audits
1.1.6.5
Site Quality Assurance Programme (SQAP)
The SQAP shall detail the Contractor's Quality Assurance Programme at Site applicable throughout site construction, erection and commissioning. It is the underlying philosophy of this Specification that the quality built into the product at Works shall be maintained throughout the construction and commissioning stages. The quality and workmanship shall be consistent with the design life of the Works. While, in principle, the SQAP shall include the items listed in WQAP, it shall, however be approached differently to take into account site conditions. The SQAP shall include typically: Organisation and Responsibility. Page 21 of 48
Ankerlig Power Station Control of Drawings and Documentation. Site Activities Checklists. Cleaning and protection procedures. Health and Safety management procedures and records. Receipt Inspection of Materials at Site. Material Storage Control. Issue of Materials and Consumables. Inspection and testing Procedures. Welding Quality Control. Non-Destructive Testing. Heat Treatment Control. Control of Painting and Insulation Works. Earthworks control checks and testing. Concrete Quality Control incl. all test results. Pre-commissioning. Commissioning. Corrective Action. Control of Inspection, Measuring and Test Equipment. Records. Quality Audits.
Specification No.
1.1.6.6
Project Specific Quality Plan (PSQP)
The Contractor is required to prepare manufacturing and site construction / erection quality plans for all plant items and services provided under the Contract based on the Contractor's standard quality assurance procedures. The quality plan shall also define the involvement of the Contractor, the Project Manager and or his inspection authority in the inspection and test programmes. The Project Specific Quality Plan (PSQP) shall incorporate typically: Charts indicating flow of materials, parts and components through manufacturing quality control, inspection and test to delivery and site erection quality control, inspection and test. The Charts shall indicate the location of hold points for quality control, inspection and test beyond which manufacture and site erection shall not continue until the action required by the hold point is met and the documentation required is generated. Document control procedure. An indication of the organisations responsible for the quality activities covered and the responsibilities of the quality assurance personnel.
Page 22 of 48
Specification No.
Reference to quality assurance procedures, goods inward procedures and non-conformance procedures, etc. The Contractor shall review and submit his sub-Contractor's quality plans and include these in the PSQP. The Contractor shall determine and agree with the Project Manager the control to be exercised over the sub-Contractors and the degree of surveillance that shall take place. Provision shall be made for the Project Manager to insert hold points at which quality control activities are to be witnessed by the Project Manager himself or his appointed inspecting authority. The Contractor shall furnish the Project Specific Quality Plan (PSQP) not later than one (1) month prior to the start of manufacture. The PSQP shall define the Contractor's organisation and responsibilities of all management including quality assurance personnel and shall detail the procedures the Contractor intends to use to manage and control those aspects of the Works which may affect the quality of the completed installation. The PSQP as revised to incorporate any comments of the Project Manager shall be considered as forming part of the Contract and any subsequent changes must be agreed in writing by the Project Manager prior to implementation. The Contractor shall implement effective planning, resourcing and control of all contracted activities by the implementation of the PSQP and associated work instructions. The Contractor shall identify its verification requirements on the PSQP submitted to the Project Manager for acceptance and shall identify the following: Stages subject to random surveillance, Inspections to be witnessed, Hold points beyond which work cannot proceed before completion of all verification and related activities. The Contractor shall establish measures for the identification and control of materials and components throughout all stages of the Contract. The Contractor shall be responsible for identifying and arranging any verification activities requiring statutory approval in the country of manufacture.
1.1.6.7
Quality Control Records/Manual
The Contractor shall maintain and provide at the end of manufacture and Works testing a manual or manuals including copies of all formal certificates, reports and results of tests and inspections related to the plant covered by the specification. This manual shall contain the approved Works certification documentation for all Plant, Equipment and services as specified in the relevant codes and standards and in this specification and the Contractors Quality Manual. This manual shall also include all mill and material test certificates. Certificates and test procedures shall be specific to the Plant supplied. Weld procedure and welder qualification certificates shall also be included. Three sets shall be provided.
1.1.6.8
Monitoring by the Employer
The Project Manager reserves the right to review and amend the proposed verification arrangements in cases where these arrangements have not been agreed prior to the order date between the Contractor and any Sub-Contractor / Supplier. During the course of the Contract the Project Manager reserves the right to monitor the implementation of the Contractors quality assurance arrangements including those of the SubContractors; where non conformances are identified the Contractor shall implement agreed
Page 23 of 48
Specification No.
corrective actions. The Project Manager shall be afforded unrestricted access to review the implementation of the corrective actions. A programme shall be established for all such audits.
1.1.6.9
Site
For Site work the Project Manager shall monitor all aspects of the Contractors daily work including his control of Sub-Contractors in accordance with the agreed procedures, compliance with Codes and Standards and the Specification, Construction Health and Safety plan and the achievement of milestone dates for the discrete work packages.
1.1.7
1.1.7.1
Safety
Contractors Obligations
In carrying out its obligations to the Employer in terms of this contract; in providing the Works; in using Plant, Materials and Equipment; and while at the Site for any reason, the Contractor complies and procures and ensures the compliance by its employees, agents, Subcontractors and mandataries with: the provisions of the Occupational Health and Safety Act 85 of 1993 (as amended) and all regulations in force from time to time in terms of that Act (the OHSA); and South African Building Codes and Construction Regulations 25207 of 2003; and Labour Relations Act; and the Eskom Safety, Health and Environmental Requirements for Contractors document attached to the Works Information (as amended from time to time) and such other Eskom Safety Regulations as are applicable to the Works and are provided in writing to the Contractor (collectively the Eskom Regulations). The Eskom Regulations may be amended from time to time by the Employer and all amendments will be provided in writing to the Contractor. The Contractor complies with the provisions of the latest written version of the Eskom Regulations with which it has been provided; and the health and safety plan prepared by the Contractor in accordance with the SHEQ Requirements. (The OHSA and the Eskom Regulations are collectively referred to as the SHEQ Requirements.) The Contractor, at all times, considers itself to be the Employer for the purposes of the OHSA and shall not consider itself under the supervision or management of the Employer with regard to compliance with the SHEQ Requirements, the Contractor shall furthermore not consider itself to be a subordinate or under the supervision of the Employer in respect of these matters. The Contractor is at all times responsible for the supervision of its employees, agents, Subcontractors and mandataries and takes full responsibility and accountability for ensuring they are competent, aware of the SHEQ Requirements and execute the Works in accordance with the SHEQ Requirements. The Contractor ensures that all statutory appointments and appointments required by any Eskom Regulations are made and that all appointees fully understand their responsibilities and are trained and competent to execute their duties. The Contractor supervises the execution of their duties by all such appointees. The Employer, or any person appointed by the Employer, may, at any stage during the currency of this contract: conduct health and safety audits regarding all aspects of compliance with the SHEQ Requirements, at any off-site place of work, or the site establishment of the Contractor;
Page 24 of 48
Specification No.
refuse any employee, Subcontractor or agent of the Contractor access to the premises if such person has been found to commit an unsafe act or any unsafe working practice or is found not to be qualified or authorised in terms of the SHEQ Requirements; issue the Contractor with a stop order should the Employer become aware of any unsafe working procedure or condition or any non-compliance with any provision of the SHEQ Requirements. The Contractor immediately reports any disabling injury as well as any threat to health or safety of which it becomes aware at the Works or on the Site to the Project Manager. The Contractor appoints a person, qualified in accordance with the SHEQ Requirements, as the liaison with the Eskom Safety Officer for all matters related to health and safety, this person shall be contactable 24 hours a day. The Contractor confirms that it has been provided with sufficient written information regarding the health and safety arrangements and procedures applicable to the Works to ensure compliance by it and all employees, agents, Subcontractors or mandataries with the SHEQ Requirements while providing the Works in terms of this contract. As such, the Contractor confirms that this contract and the relevant Eskom Regulations referred to in this contract constitute written arrangements and procedures between the Contractor and the Employer regarding health and safety for the purposes of section 37(2) of the OHSA. The Contractor agrees that the Employer is relieved of any and all of its responsibilities and liabilities in terms of Section 37(1) of OHSA in respect of any acts or omissions of the Contractor, and the Contractors employees, agents or Subcontractors, to the extent permitted by the OHSA. The Contractor hereby indemnifies the Employer and holds the Employer harmless in respect of any and all loss, costs, claims, demands, liabilities, damage, penalties or expense that may be made against the Employer and/or suffered or incurred by the Employer (as the case may be) as a result of, any failure of the Contractor, its employees, agents, Subcontractors and/or mandataries to comply with their obligations in terms of this clause 18, and/or the failure of the Employer to procure the compliance by the Contractor , its employees, agents, subcontractors and/or mandataries with their responsibilities and/or obligations in terms of or arising from the OHSA. The Contractor shall ensure that all statutory, legislative codes and regulations relating to South African and Eskoms Safety, Health and Environmental Policies and Procedures are adhered to during the design, manufacture, construction and operation of the plant up to Take Over. The Contractor shall be required to administer and control site activities in such a manner as to achieve and maintain the safety of all persons on the Site, including employees, visitors and all subcontractors. The Contractor shall make provision on all equipment, mechanical and electrical, for the placing of locks for the purpose of isolation in accordance with procedures to be agreed with the Project Manager. The Contractor shall also comply with the Project Managers reasonable recommendations regarding the temporary or permanent arrangement of ladders, gangways, working platforms, fencing of openings, posting of warning signs and the wearing of appropriate safety equipment such as safety harnesses, ear defenders etc. The wearing of safety glasses, safety helmets and safety footwear at all times by all members of the workforce including management and visitors shall be compulsory on the Site. These stipulations shall in no way release the Contractor from any obligations under Occupational Health and Safety Legislation and this Contract. A Site Safety Advisor will be appointed by the Employer and this person will act for the Employer in an advisory capacity on all matters affecting the safety of all personnel engaged on the Site.
Page 25 of 48
Ankerlig Power Station 1.1.7.1.1. Safety Surveillance Contract Requirements.
Specification No.
The Contractor shall have at least one full time experienced safety officer present on the construction site at all times during construction. The safety officers shall be suitably qualified by experience and training and shall be fully knowledgeable in South African Regulations and qualified with an technical engineering qualification, and a minimum 5 years experience in heavy construction. The safety officers brief shall be to advise the Contractor in matters of safety, to exercise general supervision of the observance of safety requirements and to promote safe methods of work. The Safety Officer Role shall be staffed by an adequate number of persons all qualified as stated above, to effectively carry out the required safety duties in a timely and effective manner. CVs for all safety officers shall be submitted to the Employer for acceptance.
1.1.7.1.2. Safety and Health Plan Before commencement of any activities on Site the Contractor shall prepare a detailed Safety and Health Plan for the Project (to include all subcontractors activities), which shall be submitted to the Project Manager for acceptance. Hard copies of the Safety and Health Plan revised in accordance with the Employers comments shall be available on site before any work commences and all subcontractors shall have signed that they have received and are familiar with the Safety and Health Plan. Detail included in the Safety and Health Plan shall include but not be limited to the following: standard safe work practices, identification of hazards including mitigation measures, personnel protective equipment requirements, plant inventory including certification, inventory of employees including record of national safe training certification, safety inductions (persons, workforce or visitors, shall not be permitted to enter the construction site(s) unless they have been registered as having received the specific site safety induction). emergency evacuation procedures including muster points, inventory of toolbox talks and attendees, site safety incentive scheme details, instructions to site security, swipe card system (in place from day one (1)), induction times, induction training facility, foreseeable risk assessment (for particular risks i.e. designation of confined spaces etc), definitions of working-at-height requirements, car parking external to site, delineation/ongoing management of lay-down, consultation arrangements weekly /monthly, site progress meetings (health and safety No 1 on Agenda), safety committee meetings (frequency agenda and persons attending), safe working procedures, Page 26 of 48
Ankerlig Power Station site perimeters, speed limit, waste management (designated skip area), readily identifiable clean up crew for contractor interface management, general site illumination and provision for change, general site signage.
Specification No.
The Plan shall indicate the Contractors requirements for new contra ctors coming to site, Insurances, site specific safety statements, training matrix (national accredited skills training certification ) proposed lay-down area etc. The Project Safety and Health Plan must address commissioning activities and develop commissioning safety rules and established plant tagging, locking systems to ensure safety and well being of all on Site. This element will be synopsised and included in induction training for all operatives coming to site.
1.1.7.1.3. Method Statements Risk Assessments (MSRA) Each different work activity must have a MSRA. MSRAs will be produced by a competent member of the Contractors team before being passed on to the Contractors safety office. Commencement of any work activity shall not take place unless a MSRA including risk mitigation has been submitted to the Project Manager, five working days in advance of any proposed commencement of the specific activity. They must be site and task specific, clear and signed off by those undertaking the task and each MSRA should be posted local to each activity.
1.1.7.1.4. Log of MSRAs At contract signing a schedule of foreseeable risks must be tied into a specific list or log up front. A monthly update of such a log must be emailed (supported by a facsimile) to the Project Manager.
1.1.7.1.5. Extent of Subcontracting The approval of sub-vendors by the Contractor must be subject to the same Health and Safety Criteria covered herein.
1.1.7.1.6. Safety File The Contractor shall provide or procure information for and prepare a Safety File. The Contractor shall provide a preliminary index of what is expected to go into the Safety File. As a minimum the Safety File shall contain all of the following: Design records relating to safety. As-built drawings of the completed plant and site. As-built process and instrumentation drawings. Records of control and instrumentation system logic and settings. Non-destructive test records. Commissioning records for all plant proving fitness for purpose.
Page 27 of 48
Specification No.
Statutory certificates for all boilers, steam receivers, steam containers, air receivers, lifting appliances and lifting gear. Operating and maintenance instructions for all plant and systems. An inventory of all hazardous substances on the plant along with all necessary safety information for the substances involved. Clearance certification where hazardous waste has been removed from the site. The Employers site teams will review progress on a weekly basis starting at commencement of work. The completed Safety File, which is required to be handed over to the Project Manager on Take Over, shall be provided in electronic form.
Page 28 of 48
Specification No.
1.2. Technical Requirements

1.2.1 Metrological Site Conditions
The equipment shall be designed as outdoor plant and the appropriate meteorological data is included in Part 5.2 - Climatic Design Conditions.
1.2.2
1.2.2.1
Working Arrangements
Planning of Work
Work must be planned carefully and in particular in case of the fuel oil storage tanks expeditiously. It would be required that the roof of the fuel tank be placed as soon as possible to reduce the risk of wind damage to the tank during construction. The contractor shall consider the method of construction such as installing the roof first tank and installing the strakes from the roof by jacking the tank upwards. All precautions necessary to ensure safety of personnel and security of supplies must be taken.
1.2.2.2
Protection of the shell during erection
The Contractor shall employ suitable methods for the protection of the shell during erection to be agreed with the Project Manager. Full details of these methods shall be made available for the Project Manager s acceptance. The factors to be taken into account when determining the suitability of the protection shall be: Tank size Construction methods Location and degree of exposure to wind loads Number and type of key plate equipment Metrological data during all periods of erection Note: The use of steel wire guys or cables may not necessarily be adequate and consideration should be given to the use of temporary wind girders
1.2.3
1.2.3.1
Storage Tanks
Terminal Points Low level nozzles at nozzle flanges and isolating valve. High level or roof mounted pipe-work routed terminal points 1m above tank base with nozzle flanges and isolating valve. Supports for cable trays including to roof instruments Foundations Contractor to advise his requirements for the tank foundations in his Contract documentation to the Employer.
1.2.3.2
Design Parameters
The diesel fuel oil and water storage system shall be supplied consisting of storage tanks as described herein and shall be in accordance with Part 2.4 Schedule C (Tank sizing). All tank roofs Page 29 of 48
Specification No.
should be self supporting in accordance with the applicable code of construction. The tanks shall be designed to last a minimum of 20 years. The Contractors scope of supply of the storage tanks must include the mechanical and process design. The Contractor shall assume the following design features: (a) (b) Corrosion allowance of 1 mm The tanks must withstand all wind forces as specified in SANS 4302;2002 / ISO 4302; Cranes - Wind Load Assessment 1981. A basic wind speed of 50 m/s (as measured at 10m above ground level) must be used in conjunction with the above wind code to derive the wind forces imposed on the tanks. Note the average hourly wind speeds in m/s are given in Sub Part 5.2 .1.2.3 (Wind) of Part 5 (Site Information Storage Tank Specification).
Every reasonable protective device for the safety of operating personnel shall be incorporated. All current safety regulations and requirements for such installations in force in Republic of South Africa shall be complied with. A contractor accepted by the Project Manager shall carry out exact calibration of the tanks.
1.2.4
4.1.1.1
Details of Tanks and Accessories Lots 1 to 2

General
The following table shall be used as a guide when sizing the fuel oil plant nozzles.
Limiting velocities Diameters NB50 80NB250 NB300
Transferring between tanks and unloading road tankers
1.0 m/s
1.0 m/s
1.0 m/s
Pump suction
0.6 m/s
1.0 m/s
1.8 m/s
In Plant
2.0 m/s
3.0 m/s
4.5 m/s
Main link
1.0 m/s
2.0 m/s
2.1 m/s
4.1.1.2
Operational philosophy of Diesel Fuel Oil tanks
Diesel Fuel tanks are required for Ankerlig Power Station and they will be arranged as shown in P&IDs 0.87/1 and 0.88/1 respectively included in Appendix E. On Atlantis there will be two tanks whereby the diesel fuel oil can be received from road tanker by either of two tanks. The normal operation is that both tanks will be nominated as the dirty receiving tanks and will therefore not require a floating suction. Diesel fuel off loading from the road tankers to the new tanks will be linked to the existing off loading bays in Ankerlig 2. Diesel fuel shall be transferred from the new storage tanks to existing Tank 3 and Tank 2. If required this will allow for one tank at a time to be taken out of service for maintenance. New storage tank selection for offloading shall be done with remote control valve selection. Tank design shall include ports and isolating valves for offline filtration system.
Page 30 of 48
Ankerlig Power Station 1.2.4.1 General
Specification No.
Part 2.4 Schedule G contains the full details of the material specifications provided by the contractor. The shell plate material shall also meet the code requirements including toughness, impact test and heat treatment. All shell vertical and horizontal joints shall be butt-welded with full penetration. Wind girders must be of the external type (if required). Roof plates to be additionally seal welded internally. The Contractor is responsible for the design, manufacture, installation and commissioning of floating suctions in the distillate fuel oil tanks including all associated pipe work and ancillaries.
1.2.4.2
Design Standards
All work shall be in accordance with the most recent edition of the relevant ASME, API, ASTM, British Standard Specification or equivalent. The distillate tanks shall be of steel circular welded construction and shall be fully compliant with: American Petroleum Institute (API), API 650: Welded Steel Tanks for Oil Storage API Recommended Practice 2350: Overfill Protection for Storage Tanks in Petroleum Facilities API 2000: Venting Atmospheric and Low Pressure Storage Tanks All dimensions and quantities shall be expressed in SI units.
1.2.4.3
Tank Drainage
A draw-off sump shall be located at the centre of each tank and the tank floor shall be adequately sloped to the sump to ensure complete drainage of water. The drainage slope shall not be less than one in sixty.
1.2.4.4
Nozzle Details and Fittings
All nozzle flanges and blanks are to be raised faced ANSI Class 150. The Contractor shall provide blanks and gaskets for all nozzles and fittings. All gaskets shall be of the spiral wound type. These may be used during the hydro-test and are to be kept as spares by the Employer on completion of the hydro-test. Additional gaskets shall be provided for those used during the hydro-test. An overflow pipe shall be piped externally to 1m above the ground level. Precise nozzle orientations will be agreed with the Project Manager. Confirmation of the precise orientation of the nozzles will be provided by the Project Manager two months after contract award. For tendering purposes a nozzle schedule has been included but tank nozzle orientation will be different for each individual tank. Nozzle allowable loadings shall be provided by the Contractor to the Employer within one month of contract award.
1.2.4.5
Materials
All materials shall be new, and of a quality most suited to the proposed application.
1.2.4.6
Instrumentation
For each tank the Contractor shall provide the level gauge and temperature gauge at eye level including isolation valves. Page 31 of 48
Specification No.
All instrumentation shall be fit for use and suitable for the hazardous zone classification of the tanks. The Contractor shall include all supports for cable trays including to roof instruments.
Page 32 of 48
Specification No.
Lot 1: Two (2) off 21000 m Distillate Fuel Tank (Welded) for Atlantis Site. Tank requirements are as follows: Tanks to have usable capacity of 21000m
3
Water draw-off sumps with necessary pipe connections to outside shell c/w external valves Three earthing bosses spaced at 120 to be located at low level Asbestos gaskets are not allowed One 750 mm external spiral stairway with intermediate landing(s) and handrail on tank and chain barriers at top and base One external ladder with intermediate landing(s) and safety cage on tank Transition landing and staircase from base of spiral staircase to ground level Gangways across tank roof to the various roof connections One handrail around periphery of tank roof. Handrails to be fitted with toe plates Sign at top of tank indicating safe load for personnel access Membrane system under tank floor Name Plate incorporating description, KKS coding, contents and code of construction Permanent wind girders where required Mechanical tank level indicators (Varec) All handrails to be of angle iron design with flat bar mid and toe plates Fill lines and main return lines to tanks to be fitted with diffusers and to conform to NFPA 30 guidelines with regards to anti-static electricity All tank internals to be removable through local manways
Nozzles shall be provided as outlined below: No. M1 M2 M3 M4 N1 N2 N3 N4 N5 N6 N7 Flowrate kg/s 168 55 66 150 66 Size NB 600 900 600 600 500 300 300 400 300 25 50 Elevation 1000 1000 Roof Roof 500 425 425 16300 425 225 1500 Description Shell manway c/w cover Shell manway c/w cover & davit Roof manway c/w cover Roof manway c/w cover Fuel supply to storage Tank 2 and 3 Fill line from unloading skid (with internal piping and diffuser Clean oil return line with diffuser from offline filtration Main return line with vacuum breaker with diffuser Feed line offline filtration system Access port for level transmitter Access port for temperature gauge Page 33 of 48
Specification No.
No. N8 N9 N10 N11 N12 N13 N14 N15 N16 N17 N18 N19 N20 N21 N22 N23 N24
Flowrate kg/s -
Size NB 50 100 250 250 100 100 100 300 400
Elevation 2000 150 Roof Roof Roof Roof Roof 425
Description Access port for temperature transmitter Sump drain at low level Tank breather on roof Tank breather on roof Dip hatch with cap and chain on roof Dip hatch with cap and chain on roof Access port for electronic level transmitter Spare fill line at ground level Balance Line
26 26
300 50 25 40 100 100 250 250
425 1500 Roof Roof Roof Roof 1500 1500
Spare fill line at ground level with diffuser Spare nozzle at low level Access port for high-high level switch Access port for local visual level indicator Access port for radar level transducer Access port for radar level transducer Fuel transfer nozzle Fuel transfer nozzle at low level with diffuser
1.2.5
Details of Tank and Accessories Lot 3
Lot 3: One (1) No. 2000 m fire water storage tank Atlantis Site
Tank requirements are as follows: The firewater tank is to be of bolted Braithwaite design Tank partitioned into two compartments each with usable volume of 1000m
3
Each compartment to be fitted with all required nozzles including raw water inlet, outlet to fire system and outlet to water treatment system Water draw-off sump with necessary pipe connections to outside shell c/w external valves Three earthing bosses located at low level Asbestos gaskets are not allowed Each compartment to have one internal ladder from base to roof manway One external ladder per compartment with safety cage on tank. Ladders shall have intermediate platforms where required by BS EN ISO 14122. Gangways across tank roof to the various roof connections Manways to have padlock facility A handrail around the periphery of the tank roof All handrails to be of angle iron design with flat bar mid and toe plates Page 34 of 48
Ankerlig Power Station Sign at top of tank indicating safe load for personnel access
Specification No.
Name Plate incorporating description, KKS coding, contents and code of construction One mechanical local visual level indicator per compartment
Nozzles shall be provided as outlined below: No. M1 M2 M3 M4 N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 N13 N14 N15 N16 N17 N18 N19 N20 N21 N22 N23 N24 N25 N26 N27 N28 Size NB 600 600 600 600 150 150 300 300 150 150 250 250 150 150 150 150 100 100 100 100 100 100 100 100 100 100 150 150 250 250 200 200 Description Shell man-way on roof - Compartment 1 Shell man-way on roof - Compartment 2 Shell man-way on roof - Compartment 1 Shell man-way on roof - Compartment 2 Fire recirculation at high level Compartment 1 Fire recirculation at high level Compartment 2 Water supply to fire-fighting at low level Compartment 1 Water supply to fire-fighting at low level Compartment 2 Spare nozzle at high level Compartment 1 Spare nozzle at high level Compartment 2 Return line from fire-fighting at high level Compartment 1 Return line from fire-fighting at high level Compartment 2 Inlet from mains water at high level Compartment 1 Inlet from mains water at high level Compartment 2 Spare fill line at high level - Compartment 1 Spare fill line at high level Compartment 2 Access port for level gauge at high level Compartment 1 Access port for level gauge at high level Compartment 2 Access port for level gauge at low level Compartment 1 Access port for level gauge at low level Compartment 2 Drain at low level Compartment 1 Drain at low level Compartment 2 Drain at low level Compartment 1 Drain at low level Compartment 2 Drain at low level Compartment 1 Drain at low level Compartment 2 Spare at low level Compartment 1 Spare at low level Compartment 2 Spare at low level Compartment 1 Spare at low level Compartment 2 Water test nozzle on roof Compartment 1 Water test nozzle on roof Compartment 2
Page 35 of 48
Specification No.
No. N29 N30 N31 N32 N33 N34 N35 N36 N37 N38 N39 N40 N41 N42
Size NB 250 250 250 250 100 100 100 100 100 100 200 200 50 50
Description Tank breather on roof Compartment 1 Tank breather on roof Compartment 2 Tank breather on roof Compartment 1 Tank breather on roof Compartment 2 Dip hatch with cap and chain on roof Compartment 1 Dip hatch with cap and chain on roof Compartment 2 Dip hatch with cap and chain on roof Compartment 1 Dip hatch with cap and chain on roof Compartment 2 Access port for electronic level measurement Compartment 1 Access port for electronic level measurement Compartment 2 Overflow at high-high level Compartment 1 Overflow at high-high level Compartment 2 Water supply to water treatment skid (located to reserve 800m for fire water) Compartment 1 Water supply to water treatment skid (located to reserve 800m for fire water) Compartment 2
3 3
1.2.6
Corrosion Protection
The tank, including the underside of the tank floor-plates, should be fully protected against deterioration from corrosion. For distillate fuel and lubrication oil the interior of the tanks shall have a protective coating system applied to the tank bases and the tank shells. For the fuel oil tanks the painting systems applied should be chemically resistant to distillate fuel oil. Similarly the painting system used for the lubrication oil tanks should be chemically resistant to the lubrication oil utilised. For water storage a suitable protective coating system shall be applied to the entire interior and exterior of the tank shell and roof. Paint shall be applied by airless spray. All handrails, stairs, ladders, support structures and catwalks shall be hot dipped galvanised.
1.2.6.1
Exterior Paint Protection System
The paint protection system proposed for application to carbon steel parts on the external shell and under-floor of the tank floor plates shall conform to EN ISO 12944 to C5-M or equivalent. The Contractor shall detail the proposed painting system and standards in Schedule H (Painting Specification) of Sub Part 2.4 (Data Schedules) of Part 2 (Tender Returnables). The colour of the paint for the exterior shall be white as agreed by the Project Manager.
1.2.6.2
Underside of Tank Floor-plates Paint Protection System
The Underside of Tank Floor-plates shall be painted with an appropriate paint protection system in sufficient time to allow paint to dry freely before placing in position for commencement of welding. The Contractor should detail the proposed painting system and standards in section Schedule H (Painting Specification) of Sub Part 2.4 (Data Schedules) of Part 2 (Tender Returnables). The Contractor should also detail the potential lifetime of the paint protection system.
Page 36 of 48
Ankerlig Power Station 1.2.6.3 Interior Paint Protection System
Specification No.
The internal of the tank shell shall be painted with an appropriate paint protection system. The tank shall be painted once the hydro-test has been completed. The Contractor should detail the proposed painting system and standards in section Schedule H (Painting Specification) of Sub Part 2.4 (Data Schedules) of Part 2 (Tender Returnables).
1.2.7
Cleanliness, Preparation, Painting, Finishing and Repairs of Painted Surfaces

Cleanliness of the System: Treatment of Internal Surfaces
1.2.7.1
Every reasonable precaution shall be taken to ensure the cleanliness of the system at premanufacture stages and during manufacture, assembly, erection and commissioning of the tank. The Contractor shall comply with the conditions stipulated in this clause over and above the normal procedures adopted for ensuring cleanliness. The Contractor and his sub-Contractors shall comply with all reasonable requirements of the Project Manager in maintaining the highest standards of workmanship and cleanliness during erection.
1.2.7.2
Protection, Painting, Finishing and Packing
The tanks shall be suitably protected at all stages of construction. Subsequent to final manufacture phase, all tank components shall be protected against deterioration due to corrosion. This requirement covers storage at the Contractors works, packing for transport, transport arrangements and storage on Site.
1.2.7.3
Surface Preparation and Conditions for Painting
All surfaces shall be dry and free of dust, salts, greases and other contaminants immediately before coating. The metal surface temperature as specified by the paint manufacturer shall be adhered to.
1.2.7.4
External Tank Painting and Under-floor Plates
Shot or grit blasting to ISO 8501-1:1988 SA 2.5 shall clean the surface. Detritus shall be removed from the surface by vacuum cleaning. The blast profile achieved shall be between 50 and 100 microns. Priming paint shall be applied within four hours of surface preparation otherwise the surfaces shall be re-prepared.
1.2.7.5
Internal Tank Painting
Shot or grit blasting to ISO 8501-1:1988 SA 3 shall clean the surface. Detritus shall be removed from the surface by vacuum cleaning. The blast profile achieved shall be between 50 and 100 microns. Priming paint shall be applied within four hours of surface preparation otherwise the surfaces shall be re-prepared.
1.2.7.6
Priming Coats Shop Priming Coat
Where the Contractor wishes to use pre-primed steel plate and sections for fabricating the plant, the shop-priming coat shall conform to the following. A priming coat of a weldable two component low build epoxy resin based zinc phosphate paint shall be applied to a dry film thickness (DFT) of 15 to 20 microns. (see API 650 section 5.2.1.9)
Page 37 of 48
Ankerlig Power Station 1.2.7.7 Post Welding Surface Treatment and Priming
Specification No.
Immediately after completion of welding, the areas of paintwork which have been affected by the welding process shall be shot blasted and primed to conform to Sub Part 1.2.7.6 (Priming Coats Shop Priming Coat) first priming coat.
1.2.7.8
Repair of Damaged Paint-work
All paintwork, which may be damaged during transport, handling, storage or erection, shall be repaired on Site as follows:
Priming Coat Damaged - External and Under-floor Plates Where the priming coat has been damaged, the damaged area shall be power wire brushed to clean metal equivalent to ISO 8501-1:1988 - St 3. This shall be followed by vacuum cleaning to remove detritus and the full paint shall be re-applied to the affected area to a total DFT of 350 microns, minimum.
Priming Coat Damaged - Internal Tank Plates Where the priming coat has been damaged, the damaged area shall be shot or grit blasted to clean metal equivalent to ISO 8501-1:1988 Sa 2.5. This shall be followed by vacuum cleaning to remove detritus and the full paint shall be re-applied to the affected area to a total DFT of 350 microns, minimum.
Potential Life of Restored Paintwork All remedial action shall restore the damaged coating to the same potential life as that of the undamaged areas.
1.2.7.9
Control of Paint Thickness
For consistent and economical application of paint, the paint film thickness shall be controlled during application by monitoring the Wet Film Thickness (WFT). A relationship shall be established between WFT and DFT beforehand by preparing and painting a suitable test plate, before preparation of metal surfaces for painting occurs.
Dry Film Thickness Method of determining the final DFT shall be to take readings over any square metre of the painted area, the average of these readings shall equal or exceed the nominal DFT and in no case shall any reading be less than 75% of nominal DFT. The same method shall be applied to determining WFT. 1.2.7.10 Areas for Special Attention
Special attention shall be given to painting of: Mating surfaces of connections Contact surfaces with concrete Interior Base of Tank Welds and areas adjacent to welds Strip coats should be applied if deemed necessary
Page 38 of 48
Ankerlig Power Station 1.2.7.11 Compatibility of Paints
Specification No.
All paints shall be by the same manufacturer and shall be compatible with one another.
1.2.8
Pipework
All pipe-work for fuel storage shall be API 5L grade B schedule 40. All pipe-work for water storage shall be to galvanised carbon steel (ASTM A106 grade B or API 5L B).
1.2.9
Tank Labelling
The Contractor shall provide labelling on the tank stating the tank number and the type of (liquid) fuel it contains. This should be clearly seen from the outside of the bund.
1.2.10
Civil Requirements
Materials for Civil Works
1.2.10.1
The Contractor shall supply all embedded anchor bolts, jacking posts, sleeves, anchors and other miscellaneous embedded parts necessary for the installation of the tanks and required to be incorporated in the civil works, including, if necessary, setting templates required for anchor bolt placement. A civil contractor will incorporate all such items into the structures under a separate contract. Materials shall be supplied and proper and sufficient drawings and templates shall be provided in sufficient time to ensure the items are incorporated in the civil works.
1.2.10.2
Information for Civil Works
Information required for the timely planning, design and construction of the civil works shall be provided by the Contractor as required. The Contractor provides all the necessary information in the detail required and at the appropriate time. The Contractor specifies any specific requirements for tank foundations taking into consideration local conditions. Information shall be provided at three levels of detail namely outline, basic and definitive. Outline information shall include the main dimensions and arrangement planning of structures together with preliminary plant loads. Basic information shall be at such level of detail as to allow the execution of calculations to within an accuracy of +10% and the preparation of draft drawings. Basic information shall be provided within 1 week of contract award. Definitive information shall provide final definitive loading information and allow the preparation of detailed execution and construction drawings for the civil works. Definitive information shall be provided within 4 weeks of contract award. The information to be provided shall include the following: Design Calculations Arrangement drawing indicating detailed tank geometry Loadings imposed by tank and equipment Criteria for settlement of tank foundations
Page 39 of 48
Specification No.
Details of all plinths, openings, box-outs holding down arrangements, grouting etc., required for tank
1.2.11
Final Information to be Supplied before Contract Completion
A technical file for the Storage Tanks shall be submitted prior to the Completion Date. A Table of Contents for the technical file shall be submitted to the Project Manager for comment and review prior to the compilation of the technical file. Four hard copies of all documentation shall be submitted before the Contract is deemed to be complete. In addition to the hard copies a soft copy shall also be submitted, with all files in their native application. The Contractor shall supply complete descriptive details and as built drawings of the tanks, giving full particulars of the materials used. The Contractor shall submit detailed loading values of the tank giving the maximum loads. Any point loads shall be identified and their location detailed on a drawing. The Contractor shall submit a detailed record of material certificates, the plate preparation, welding and NDE records, and hydro-test results.
Page 40 of 48
Specification No.
1.3. APPENDICES
Page 41 of 48
Specification No.
1.3.1
APPENDIX A CODES AND STANDARDS

th
API 2000, 5 Edition, Apr. 1998 API Recommended Practice 2350, 3 Edition, Jan. 2005
th rd
Venting Atmospheric and Low-Pressure Storage Tanks Overfill Protection for Storage Tanks in Petroleum Facilities Welded Steel Tanks for Oil Storage British Standard Specification for Manufacture of vertical steel welded non-refrigerated storage tanks with buttwelded shells for the petroleum industry Specification for the design and manufacture of site built, vertical, cylindrical, flat-bottomed, above ground, welded, steel tanks for the storage of liquids at ambient temperature and above Safety of machinery Permanent means of access to machinery Storage and Handling of Flammable and Combustible Liquids Guideline to Acceptance of Contractors Drawings Eskom Plant Safety Regulations Drawing numbering system Specification for Storage Tanks Requirements For Protective Coatings For Use At Koeberg Nuclear Power Station Eskom Documentation Standard ISO pipe threads for pipes and fittings where pressure tight joints are made on the threads. Steel pipe flanges Electric welded low carbon steel pipes for aqueous fluids (ordinary Duties) Hot-dip (galvanized) zinc coatings Rubber joint rings (non-cellular) for use in water, sewer and drainage systems Storage and distribution of petroleum products in aboveground bulk installations The classification of hazardous locations and selection of electric apparatus for use in such locations Identification Colour Markings National colours for paint Quality Management systems and standards
API Standard 650 10 Edition, Nov. 1998 BS2654:1989
EN14015: 2004
BS EN ISO 14122 (Part 1 to 4 inclusive) ESKAMAAD1 Rev 2 GGG 0450 GGR 0992 GGS 0445 GGSS 0317 KSA-106 OPS 0002 SABS 1109 SABS 1123 SABS 719 SABS 763 SABS 974-1 SANS 10089-1:2003 Part 1 SANS 10108 SANS 10140-3 SANS 1091 SANS 9000 to 9004
1.3.2
Page 42 of 48
Specification No.
1.3.3
APPENDIX B ABBREVIATION LIST
BOP C&I DCIS EN ESV FAT GRP GT HMI HV LCS MCB MCC NB NEC NDT NERSA NFPA OCGT OEM OHSA O&M PCC PLC PIP PPE PSQP P&ID QAM SANS SAT SHEQ SI SQAP SWL
Balance of Plant Control & Instrumentation Distributed Control and Information System European Norm Emergency Stop Valve Factory Acceptance Test Glass- Reinforced Polyester Gas Turbine Human Machine Interface High Voltage Local Control Push Button Station Miniature Circuit Breakers Motor Control Centre Nominal Bore New Engineering Contract Non-Destructive Testing National Energy Regulator of South Africa National Fire Protection Association Open Cycle Gas Turbine Original Equipment Manufacturer Occupational Health and Safety Authority Operation and maintenance Power Control Centre Programme Logic Control Project Implementation Plan Personal Protective Equipment Project Specific Quality Plan Piping and Instrumentation Diagram Quality Assurance Manual South African National Standard Site Acceptance Test Safety, Health, Environment & Quality International System Site Quality Assurance Programme Safe Working Loads
Page 43 of 48
Specification No.
WPS WPAR WQAP WQR
Welding Procedure Specification Weld Procedure Approval Records Works (Manufacturers Facility) Quality Assurance Programme Welder Qualification Records
Page 44 of 48
Specification No.
1.3.4
APPENDIX C SAFETY, HEALTH AND ENVIRONMENTAL
Appendix C - Section 1 Ankerlig Safety, Health & Environmental Specification
Page 45 of 48
Specification No.
Appendix C - Section 2 Environmental Report
Page 46 of 48
Specification No.
1.3.5
APPENDIX D - CORROSION PROTECTION
Page 47 of 48
Specification No.
1.3.6
APPENDIX E - DRAWINGS
The following Drawings are included in the enquiry:
Atlantis Ankerlig 2 Site 0.88/1 0.88/4 0.88/8 0.88/28 RSA805-UC07-UZ-110001 Station Layout P&ID Demineralised Water System P&ID Fire Water System Fire water storage tank Siemens Layout Showing Terminal Points
Page 48 of 48

Ankerlig Additional Storage Tanks

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Ankerlig Additional Storage Tanks

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Ankerlig Power Station

Ankerlig Power Station

Ankerlig Power Station

Additional Diesel Storage

Leonard Calana Tinus Keyser

DATE: 6 December 2011

DATE: 6 December 2011

Rodney Booth Plant Manager

DATE: 6 December 2011

Latest Revision Summary:

Ankerlig Power Station

TABLE OF CONTENTS Page No.

GENERAL REQUIREMENTS .................................................................................6

Ankerlig Power Station 1.1.5.8

Personal Protection Equipment ................................................................................................. 19

TECHNICAL REQUIREMENTS ............................................................................ 29

Ankerlig Power Station 1.2.7.9 1.2.7.10 1.2.7.11 1.2.8 1.2.9

Pipework .......................................................................................................................................... 39 Tank Labelling ................................................................................................................................. 39

Ankerlig Power Station

1.1. General Requirements

Permits and Licenses

Scope of the Works

Ankerlig Power Station

Site Conditions Access and Contractors Area

Co-operation with Other Site Service Providers/Good Neighbours Policy

Ankerlig Power Station 1.1.2.5.2. Other Service Providers

Manner of Execution - Personnel

Ankerlig Power Station 1.1.2.11 Contractor's Representatives and Personnel

Statutory Requirements, Codes, Building Regulations

Ankerlig Power Station

Competence of Welders and other Personnel

Welders and Welders Qualification - General

Ankerlig Power Station

Ankerlig Power Station

Ankerlig Power Station

The number of copies required is four (4).

Ankerlig Power Station

1.1.4.12.5. Quality Control Records/Manual Refer to section 1.1.6.7 in this document.

Plant Identification System

Ankerlig Power Station

Ankerlig Power Station 1.1.4.14.3. Site Welding

Inspection and Tests

Ankerlig Power Station 1.1.4.15.3. Weld Repairs

Ankerlig Power Station 1.1.5.2 Water Supply

Washing and Sanitary Facilities

Personal Protection Equipment

Ankerlig Power Station

Quality Assurance, Concept and Control

Quality Assurance Manual (QAM)

Works (Manufacturers Facilities) Quality Assurance Programme (WQAP)

Site Quality Assurance Programme (SQAP)

Project Specific Quality Plan (PSQP)

Ankerlig Power Station

Quality Control Records/Manual

Monitoring by the Employer

Ankerlig Power Station

Ankerlig Power Station

Ankerlig Power Station 1.1.7.1.1. Safety Surveillance Contract Requirements.

Ankerlig Power Station

Ankerlig Power Station

1.2. Technical Requirements

Protection of the shell during erection

Ankerlig Power Station

Details of Tanks and Accessories Lots 1 to 2