PA

ABOVE GROUND FIRE PUMP (Please change this description to suit your job)

PA.1

GENERAL :

PA.1.1

DESCRIPTION
The work required under this Contract will be for the manufacture, factory testing,
delivery to Site, offloading, storage (if necessary), installation, site testing and
commissioning of two treated water pumps and motors, one jockey pump,
associated pipework, valves, etc. within the pumping station to 1m outside the
pumping station together with all the necessary electrics and controls.

PA.1.2

PUMP CHARICTERISTIC CURVES

Within as short a time as possible but not later than 2 weeks after the award of the
Contract, the Contractor shall supply to the Engineer, the proposed pump characteristic
curve and suppliers data sheet for approval.

PA.1.3

PLANT DRAWINGS
Within as short a time as possible but not later than 2 weeks after the award of the
Contract, the Contractor shall supply to the Engineer, in triplicate, fully dimensioned
drawings of the plant and equipment to be supplied by him and details of the positions of
all foundations, bolt holes, openings in walls or floors and other special features affecting
the construction of the works so that the Engineer can approve such details and size.

PA.1.4

INSTALLATION PROGRAMME
Within 1 week after the award of the Contract the Contractor shall furnish, in triplicate, a
consolidated programme in the form of a bar chart or other suitable format showing
separately, in sufficient detail, each major operation with critical operations clearly
identified. All future revisions of the programme shall be of the same format as of that
initially submitted. In preparing his programme the Contractor shall make due allowance
for the fact that work under the Civil Engineering aspects of the Contract, will be
proceeding simultaneously.

PA. 1.5

DELIVERY AND STORAGE

Immediately any consignment of plant or materials under the Pumping Plant aspect of
the Contract is despatched, and four days prior to despatch by road transport, the
Engineer's Representative must be notified and an additional advice note shall be
forwarded to the Engineer, giving a full description of the plant and materials despatched,
date of consignment and details of the transportation.
No covered storage is available on site for the plant and equipment to be supplied. The
Contractor will, however, be permitted to store non-perishable items on site in the open
air at his own risk. Apart from any materials stored thus, all plant and materials to be
supplied under this Contract shall be stored at the Contractor's expense, either in his own
stores or in stores arranged by the Contractor nearer to site and delivered to site only
when installation is required. All costs of storage and delivery to site shall be deemed to
have been included in the Schedule of Prices.
All plant, equipment, apparatus and pipework likely to be damaged in loading or
unloading, or through chafing or through being subjected to pressure, or likely to

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SS1

deteriorate through exposure to the atmosphere whilst in storage, is to be suitably

packed so as to prevent such damage.
PA.1.6

STANDARDISATION
In order to simplify maintenance and minimise stocks of spares, the Contractor shall
standardise components supplied under this Contract as far as is reasonably practicable.

PA. 2

MATERIALS AND WORKMANSHIP :

PA. 2.1

MATERIALS - GENERAL

PA.2.1.1

All materials used and plant supplied shall be of adequate quality and the most
appropriate of their kind in accordance with the best accepted modern practice; they
shall be suitable for working at the pressures and temperatures involved, under all
operating conditions, without distortion or deterioration or the setting up of undue
stresses in any part.

PA.2.2

STANDARDS AND SAMPLES

PA.2.2.1

STANDARDS:
The latest editions and amendments of the following Standards and Codes shall be
considered a minimum requirement, and the entire installation shall comply with these
Standards and Codes of Practice unless otherwise specified elsewhere in this document
or dictated by Government, Supply Authority or Local Authority By-Laws and Provisions :
(i)

The SABS Code of Practice for the Wiring of Premises.

(ii) The Occupational Health & Safety Act 85 of 1993.

(iii) South African Bureau of Standards Specifications and Codes of Practice
(SABS).
(iv) British Standards and Specifications and Codes of Practice (BSS/CP).
(v) IEC Standards and Codes of Practice.

.
(vi) ASIB Automatic Sprinkler Inspection Bureau (Pty) Ltd Rules
National Standards and Codes of Practice take priority over foreign Standards and
Codes, and where National Standards and Codes do not exist, the relevant BSS and IEC
Codes shall apply in that order of preference.
Notwithstanding anything to the contrary, the most onerous condition will be deemed to
apply, in the event of any ambiguity or conflict between applicable Standards,
Specifications and/or Codes of Practice which could arise.
PA.2.2.2

SAMPLES:
Samples of equipment and material intended for use in the installations may be
requested by the Engineer before work is commenced and such samples may be
retained until completion of the Contract. Copies of the relevant standard test reports
shall be submitted to the Engineer on request.

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SS2

Notwithstanding the foregoing, the Contractor shall satisfy himself as to the suitability of
all materials supplied by him for the purpose required. It shall be deemed that the prices
included in the Schedule of Quantities/Prices have allowed for the provision of such
samples, tests and test reports unless otherwise stated in the Specification.
PA.3.

STRUCTURAL STEELWORK

PA.3.1

The structural steel used in this Contract shall be to SABS 1431 Grade 300 W.

PA.3.2

Black bolts and nuts shall be in accordance with SABS 135.

PA.3.3

Black metal washers shall be in accordance with BS 3410.

PA.3.4

High strength friction grip, bolts, nuts and washers shall be in accordance with
SABS 1282, and their application shall conform to SABS 094, torque wrenches or impact
tools where used shall be re-calibrated before each shift.

PA.3.5

All fabrication and erection procedures shall be in accordance with SABS 0162 as
amended, Part 2, Chapter 5.

PA.3.6

Before commencing the fixing of the steelwork the Contractor shall check the seating for
line, level and bolt setting, and any errors which cannot be accommodated shall be
immediately reported to the Employer.

PA.4.

STEEL FABRICATION AND BASEPLATES

PA.4.1

The manufacture of all fabricated items of plant shall be generally in accordance with
SABS 0162.

PA.4.2

The fabrication and manufacture of the plant and equipment shall be completed in the
Contractor's workshops before delivery to site.

PA.4.3

No fabrication of complete units shall take place on site. Site work shall be confined only
to such alterations and adjustments as are found to be necessary during erection.

PA.4.4

If major alterations are found necessary, the items of plant concerned shall be returned to
the Contractor's workshops for modification or replacement and shall be tested and
checked before re-delivery to site.

PA.4.5

Drive baseplates shall be robustly constructed and adequately stiffened to prevent

twisting and distortion.

PA.4.6

Any fabricated baseplates shall be of all-welded construction and formed of hot rolled
mild steel plates and sections.

PA.4.7

Where driving units are directly coupled to the driven component all mounting surfaces
shall be machined to ensure correct alignment. Shims may be provided to aid final
alignment. After final shop assembly and testing, the individual items of plant shall be
accurately dowelled and bolted in position on the baseplate to prevent any misalignment
during transportation and installation or during operation.

PA.4.8

The Contractor shall include in the design for any measures required to counter the
effects of vibration which might be caused by the operation of the equipment; such
vibration should however be minimal and in accordance with the appropriate standard.

PA.4.9

The baseplates shall be designed in a manner which will enable the Contractor to ram
grout under the support frame without cutting of the baseplate such that the baseplate
support faces are in full contact with the grout.

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SS3

PA.4.10

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A stainless steel (3CR12) drip tray must be provided under the pump/motor shaft to
collect any water passing the gland.

SS4

PA.5.

STEEL PIPES :

PA.5.1

STEEL PIPES AND COATINGS

Except in cases where steel pipes and fittings are to be used in compliance with Section
II Materials and Workmanship, Clause PA 8 hereof, all steel pipes and fittings shall be
lined and coated and shall be in compliance with SABS 719 or BS 534. The lining and
coating of such pipes and fittings shall be set out in Section II Materials and
Workmanship, Clause PA 20.

PA.5.2

STEEL PIPES ARC WELDING PROCEDURE:

All welding is to be carried out by Certificated or Coded welders.
The welders shall possess one or more of the following certificates of competency :(a) ASME Section 9 for Position 6.g
(b) Welding certificate for positional welding in accordance with SABS Code of
Practice.
(c) Welding certificate for positional welding in accordance with BS 4872 Part 1.

PA.5.2.1

First Welds on Steel Piping:

All first welds on steel piping shall be Argon Arc welds followed by arc welding. Small
bore piping with diameter less than 25mm shall be totally Argon Arc welded. Metal Arc
welding shall be in accordance with Technical Memorandum T.3 issued by the British
Welding Research Association.

PA.5.2.2

Inadequate Penetration and Lack of Fusion:

Any individual defect due to inadequate penetration or lack of fusion shall not exceed
12mm in length. The total length of any such defects in any 300mm length of weld shall
not exceed 12mm. Individual defects shall be separated by at least 150mm of sound
weld metal. If the weld is less than 300mm then the total length of such defects shall not
exceed 5% of the total weld length.

PA.5.2.3

Slag Inclusions - Welds:

The maximum width of any isolated slag inclusions shall not exceed 1,5mm and the total
length of any such inclusions shall not exceed one and a half times the nominal wall
thickness. Adjacent inclusions shall be separated by a minimum of 50mm of sound weld
metal.

PA.5.2.4

Porosity:
The maximum dimensions of any individual gas pocket shall not exceed 1,5mm.
Clustered or scattered porosity throughout the weld will be adjudicated on its merits by
the Engineer, whose decisions will be final.
Careful consideration must be given to temperatures and pressures.
No weld containing cracks, regardless of shape, size or location will be accepted.

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SS5

PA.5.2.5

Undercutting:
Undercutting shall not be V-shaped, nor shall it exceed 0,75mm or 12% of the pipe wall
thickness, whichever is the smaller in depth, nor shall it exceed 50mm in length or 1/6th
of the length of the weld, whichever is the smaller.
Undercutting adjacent to the root bead on the inside of the pipe shall not exceed 50mm in
length, or 1/6th of the length of the weld, whichever is the smaller.

PA.5.2.6

Repair of Removal of Defects:

Defects, except cracks, in the root and filler beads may be repaired only with the prior
consent of the Engineer. A butt weld containing any form of cracks shall be removed in
its entirety. All repairs to welds must meet the specified standards of acceptability.
Before a repair is made, injurious defects shall be entirely removed down to clean metal.
All slag and scale shall be removed by grinding or wire brushing. Pre-heating of a local
repair area may be called for by the Engineer. Any repaired areas shall be reradiographed, or inspected by the same means previously used.
The Employer reserves the right to re-inspect the whole of any repaired weld.

PA.5.2.7

Pipe Bends or Specials:

Where reducers, bends or tees are required, suitably drawn and formed fittings,
compatible with the pipes, may be used. All fabricated fittings shall be approved by the
Engineer and the wall thickness of the bends or specials increased to the next
standard wall thickness of the adjacent piping (viz. 4,5 mm thick Grade A steel pipe bends or specials therefor shall be 6mm thick Grade A steel pipe etc.)

PA.5.3

STEEL PIPE - GAS WELDING PROCEDURE

PA.5.3.1

Oxy-acetylene welding shall generally be carried out in accordance with the

"Recommended practice of oxy-acetylene welds in Mild Steel Pipelines" published by the
Heating and Ventilation Contractors Association.

PA.5.3.2

The Contractor shall obtain from the manufacturers test certificates representative of
welding rods and electrodes used in accordance with BS 1453 or BS 639 respectively.

PA.5.3.3

All welded joints, whether produced by oxy-acetylene flame or metal-arc processes shall
be of first-class quality. The butts shall be slightly convex with regular ripples and no
undercutting washing away or surface cavities shall be present. Notches at the root
indicating incomplete penetration and excessive weld protruding into the pipe bore in
excess of 1,5mm will not be accepted and the external reinforcement shall run out
smoothly to the pipe surface on either side. All slag shall be removed after each run.
Undercut edges, slag pockets, unsound metal and blowholes shall be chipped out as the
work proceeds.

PA.6.

POLYPROPYLENE PIPE WELDING PROCEDURE

PA.6.1

PE, PP and uPVC pipes shall comply with SABS 533 Part II, SABS 1315 or SABS 966
respectively for water supply purposes and shall be weather resistant and UV Stabilized
where installed above ground. Joints and fittings for unplasticized PVC pipes shall be to
BS 4346.

PA.6.2

Unplasticized PVC pipes for drainage purposes shall be to SABS 791 and SABS 967 for
underground and above ground systems respectively.

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SS6

PA.7

VALVES

PA7.1

SLUICE VALVES:

These shall be cast iron standard waterworks pattern valves double flanged for steel
pipes and plain-ended for uPVC mounted pipes.
The valve wheels or handles shall be clockwise closing with non-rising stainless steel
spindles. Direction of closing shall be clearly marked on the hand-wheel.
The sluice valves shall comply with the requirements of SABS 664 for Waterworks Gate
Valves up to Class 25, SABS 665 for Industrial Gate Valves up to Class 25, SABS 191
for Steel High Pressure Gate Valves for both Waterworks Pattern and Industrial Pattern
greater than Class 25.
PA7.2

BUTTERFLY VALVES:
These shall be cast iron double flanged valves of perfect closure. The valves shall be
fitted with stainless steel shafts and discs and natural rubber or neoprene seats and
shaft seals.
The valves shall comply with BS 5155 - 1984.

PA7.3

REFLUX VALVES:
These shall be double flanged and shall comply with the requirements of SABS 144 for
swing - check types.
Reflux valves shall be so designed that when mounted horizontally the flap rests
against the seat in the absence of flow or pressure without the aid of springs or
counterweights

PA8.
PA8.1

FLANGES
Flanges for pipes and specials shall be parallel faced truly at right angles to the bore or
branch and machined over the full width of the contract face. Dimensions and drilling
shall be in accordance with SABS 1123 unless otherwise specified and where used shall
be bonded at three places on the circumference of the pipeline to the adjacent pipeline.
Puddle flanges shall be of similar dimensions as standard flanges but un-drilled and unmachined.

PA.9

PA9.1

PA10.
PA10.1

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JOINTING MATERIALS
Flanged joints shall be supplied complete with full face 3mm reinforced butyl rubber for
low pressure or CAF for high pressures or other approved joint rings and with all bolts,
nuts and washers and of adequate strength to withstand the local stresses and pressures
of the pipeline, fitting or special at its position in the system. The physical properties of
the gasket material shall be appropriately chosen for the type of fluid to be transported
and shall be chemically stable.

FLEXIBLE PIPE COUPLINGS

The Contractor is at liberty to provide any type of flexible coupling for the pipes specified
above subject to the approval of the Employer. Couplings shall generally however, be of
a type without a central register and shall be capable of being assembled without
distorting or damaging the joint ring; all necessary bolts, nuts and rings shall be
SS7

provided. Each coupling shall have a test rating equal to or greater than that of the pipes
which it connects. Flexible couplings in the ground shall be encased in corrosion
protective material and bonded in three places on its circumference to the adjacent
pipeline on both sides of the coupling.

PA11.
PA11.1

WATER PIPE TESTING

Water piping shall be tested as required with a water pressure of not less than 1 times
the maximum working pressure or the maximum surge pressure whichever is the greater.
Care shall be taken to avoid putting excessive pressures on mechanical seals, safety
devices, etc. The system shall be filled and all air vented at least 24 hours before the
actual test pressure is applied. Test pressure shall be maintained for not less than 30
minutes and must hold its pressure to the satisfaction of the Employer after the force
pump has been disconnected. Leaks in screwed fittings shall be corrected by remaking
the joints. Welded joints shall be cut out and re-welded if leaks occur from them.
Caulking of leaks will not be permitted.

PA12.

METAL WALKWAYS

PA12.1

All metal walkways shall be made of square pattern gratings with 30mm openings,
40 x 5mm bearer bars and a mass of not less than 50 kg per square metre. Chequer
plate shall not be used for walkways. The gratings shall be galvanised and further
treated as required in accordance with Clause 15 of this Specification.

PA13.
PA13.1

BOLTS, NUTS & WASHERS

All bolts and nuts shall have preferably metric threads of coarse pitch series but those
supplied as part of proprietary equipment will be accepted in accordance with the
manufacturers Standard. Washers shall be provided at each nut and shall be of the
same materials or coating where applicable to match the bolt and nut.
Single coil spring washers shall be fitted to all bolts subject to vibration. All bolts shall
project not more than 6mm and not less than 3mm from the heads of the nuts when fixed
and shall have not more than four threads within the thickness to be bolted up.
All anchor bolts for machinery shall be galvanised or of similar metal resistant to
corrosion attack but not painted. They shall be protected so as not to set up electrolytic
action between the bolts and the surrounding equipment.

PA.14

GALVANISING

PA.14.1

All hot-dip galvanising shall be executed in accordance with the Code of Practice
SABS 0214 - 1987 governing the design, fabrication and inspection of steel for hot-dip
galvanising in conjunction with SABS 934 and SABS 763 governing the quality of hot-dip
galvanising, with particular reference to the following requirements. SABS 934 for hot dip
galvanised zinc coatings on steel sheet and strip. SABS 935 for hot dip galvanised zinc
coatings on steel wire.

PA.14.2

Mild steel plate and sections shall be of good commercial quality, or higher grades, best
suited for galvanising, The material shall be free from slag or coarse laminations,
fine fissures and rolled-in impurities.

PA.14.3

Castings shall be sound, dense and clean and free from distortion, porosity, carbon and
slab enclosures, blow-holes and other injurious conditions.

PA.14.4

Folded, rivetted or similarly jointed metal constructions shall not be acceptable.

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SS8

PA.14.5

Welding flux shall be chipped away and all welds wire brushed before galvanising.

PA.14.6

The surfaces to be galvanised shall be free from paint, oil, grease, rust and similar
impurities.

PA.14.7

All exposed surfaces including welds shall be thoroughly sand blasted prior to
galvanising.

PA.14.8

The Engineer shall have the right to inspect all steel components before galvanising, and
to reject or ask for remedial treatment of any material which is considered to be
unsuitable. This applies particularly to welds.

PA.14.9

The galvanised coating shall be smooth, adherent, continuous and free from black spots
or flux stains.

PA.14.10

Globular extra heavy deposits of zinc which interfere with the intended use of the material
shall not be acceptable. Excessively protuberant lumps and nodules shall be removed
by hot wiping or by the skilful application of mechanical means. However, there shall
remain a sufficient minimum thickness of unbroken zinc coating. Flaws on small parts
and working surfaces shall be repaired only by stripping and re-dipping. The zinc bath
shall contain not less than 98,5% pure zinc.

PA.14.11

Installation in areas which are not classified as hygiene areas, are subject to less
stringent requirements.

PA.14.12

The deposits from galvanised coatings shall be as follows :MATERIAL

THICKNESS

COATING GRAMS PER

m

APPROXIMATE
THICKNESS

5 mm and over

760

0,108 mm

5 mm to 2 mm

535

0,07 mm

2 mm to 1,25 mm

400

0,056 mm

Bolts and Nuts

PA.15.

PAINTING :

PA.15.1

GENERAL CLAUSES

275 - 300

0,033 mm
0,036 mm

All preparation and painting shall be in accordance with SABS Standards.

Where painting takes place, surrounding floors, walls, structures, plant and
equipment shall be protected against spillage and in case of accidental spilling,
thoroughly cleaned.
Such work is to be properly supervised throughout the contract.
All painting is to be undertaken in accordance with the appropriate SABS Standards and
the following directives must be considered :PA.15.1.1

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Paint shall not be applied over any surfaces containing traces of grit, grease, oil, loose
rust, loose millscale or corrosion products of any kind.

SS9

PA.15.1.2

All metal surfaces to which paint is applied shall be moisture free. Paint surfaces which
are to be overcoated shall be hard dry before overcoating, unless the specification states
otherwise.

PA.15.1.3

All traces of soluble salts and corrosive air-borne contaminants shall be thoroughly
washed from the surface prior to painting, and the surfaces dried and repainted
immediately thereafter.

PA.15.1.4

Unless otherwise stated, no paint shall be applied within 50mm of areas which are to be
welded.

PA.15.1.5

Welds and adjacent parent metal shall be de-slagged, inspected and approved and all
spatter shall be removed prior to painting.

PA.15.1.6

The weld areas shall be abrasive blasted and/or ground and all contaminants shall be
removed prior to painting. Wire brushing of the weld shall only be allowed if the Paint
Specification calls for wire brushing. The weld area shall then be flushed with fresh water
and allowed to dry before receiving the full specified paint system.

PA.15.1.7

Surfaces which are to rest on concrete or other floors shall receive the full paint
system prior to erection.

PA.15.1.8

Areas where the paint coating has been damaged during transportation, erection or by
any means whatsoever, shall be repaired as follows :Rust spots shall be removed by means of a wire brush or emery paper and the
surrounding paint which is still intact shall be feathered for a distance of 20mm beyond
the damaged area. Spot priming shall consist of all the coats previously applied, and
shall overlap the damaged area by 20 mm.

PA.15.1.9

Where the shop coat has been allowed to age for a few months before painting, it shall
be light sanded or rubbed with steel wool or scrubbed with clean water, using a bristle
brush.

PA.15.1.10

Mating of contact surfaces shall be protected from corrosion by ensuring that the two
surfaces brought into contact with each other shall be prepared and primed in
accordance with the specification. The primed surfaces shall be brought together while
the paint is still wet.

PA.15.1.11

Areas which will be inaccessible after erection shall receive the full approved coating
system, before erection or assembly.

PA.15.1.12

Unless otherwise specified, steel embedded within concrete shall not be painted except
to within 50mm below the concrete/air interface.

PA.15.1.13

All sharp edges and cut ends shall receive the specified dry film thickness of paint.

PA.15.1.14

All air used for blast cleaning or spraying shall be free from all traces of water and oil.

PA.15.1.15

When blast-cleaning, a satisfactory blast profile (i.e. anchor pattern) shall be achieved. If
the abrasive used for blast-cleaning is sand, it shall be free of clay.
The abrasive shall comply with SABS 064 "Code of Practice" and shall be free from oil
and grease and corrosive contaminants such as chlorides and the like.

PA.15.1.16

The Contractor shall ensure that the manufacturer's recommended thinners are used for
any particular paint.

PA.15.1.17

The Contractor shall ensure that the final finishing coat obscures the previous coat.

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SS10

PA.15.1.18

The Contractor shall ensure that primed steelwork which is to be delivered to site is
stacked on bearers and is clear of the ground. Wherever possible channels, angles, etc,
shall be stacked so that water cannot collect on steel.

PA.15.1.19

Surfaces which are to be friction bolted, shall be prepared in accordance with the
specification (i.e. blast cleaned or wire brushed), but shall receive no paint coating.

PA.15.1.20

Paint dry film thickness shall be measured using a non-destructive thickness gauge such
as the "Mikrotest" or equivalent.

PA.15.1.21

The paint manufacturer's instructions shall be strictly adhered to.

PA.15.2

PAINTING OF STEEL SURFACES WITH POLYURETHANE

This system is based on a polyurethane which is cured with an Aliphatic Di-Isocyanate.
No polyurethane products which are cured with Aromatic Di-Isocyanate curing agents will
be acceptable. This system shall be used in highly corrosive conditions and where
a high quality finish is required.

PA.15.2.1

In Fabricator's Premises:
(a) Surface Preparation:
All steel surfaces shall be abrasive blast-cleaned to an SA 2 (near white) finish to
Swedish Standard 05/59/00.
(b) Primer:
Apply one full coat by spray of Inorganic Ethyl Silicate Zinc Rich Primer to give a
Minimum dry film thickness of 45 microns.
(c) Undercoat:
Apply one coat of Micaceous Iron Oxide High Build Epoxy (Dark Grey) to give a
minimum dry film thickness of 45 microns.

PA.15.2.2

On-site Painting of Steelwork:

(a) Undercoat:
Unless the undercoat has already been applied it shall be applied before erection as
described in Sub-clause (c) above.
(b) Finishing:
Two (2) finishing coats of approved polyurethane enamel in the approved colour,
shall be applied go give a minimum dry film thickness of 25 microns per coat. The
two coats shall be distinguishable in colour and the second coat shall be applied
within 24 hours of the first.
The total minimum dry film thickness for the complete paint system shall be 140
microns.

PA.15.3

PAINTING OF MOTORS, GEAR BOXES, PUMPS AND OTHER EQUIPMENT:

PA.15.3.1

Surface Preparation:
This paint system shall apply to areas in low corrosive conditions.

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SS11

The surfaces to be painted shall be wire brushed to an St 3 finish to SIS 05/59/00 and
shall be completely free from oil, grease, rust and foreign matter of any kind.
PA.15.3.2

Priming:
One (1) coat of an approved Inorganic Zinc Epoxy Primer shall be applied to form a
uniform coat with a minimum dry film thickness of 60 microns and to fill all porosities in
the castings. After 24 hours the primer shall be wet sanded to produce a uniform,
smooth surface.

PA.15.3.3

Undercoat:
One (1) coat of a suitable undercoat to a minimum dry film thickness of 30 microns in
accordance with SABS 681, Type 2, tinted to a shade just lighter than the finishing colour
with a suitable staining agent compatible with the paints shall be applied.

PA.15.3.4

Finishing:
One coat of approved high gloss enamel to a minimum dry film thickness of 30 microns
in the approved colour shall be applied in accordance with SABS 630.
The total dry film thickness for the coating system shall not be less than 120
microns.

PA.15.4

PAINTING OF PIPES, VALVES AND FITTINGS

This paint system shall be used in areas of low corrosive conditions.

PA.15.4.1

Surface Preparation:
The surfaces shall be wire-brushed to an St 3 finish to Swedish Standard SIS 05/59/00 to
remove loose rust and millscale.

PA.15.4.2

Priming:
One approved coat of primer in accordance with SABS 679, Type I, shall be applied to a
minimum dry film thickness of 30 microns.

PA.15.4.3

Undercoat:
Undercoat shall be as specified in 21.4.3.

PA.15.4.4

Finishing:
The finishing coat shall be as specified in Clause 21.4.4.
The total dry thickness for the coating system shall not be less than 90 microns.

PA.15.5

PAINTING OF GALVANISED SURFACES

A setting time of one week must be allowed before the application of the final coat.

PA.15.5.1

Surface Preparation:
The surfaces shall be cleaned using a galvanic iron cleaner.

PA.15.5.2
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Priming;
SS12

To the cleaned surfaces apply a base coat of Prolux D 193-0839 or approved alternative
to a minimum dry film thickness of 25 microns.
PA.15.5.3

Undercoat:
Apply one coat of high build chlorinated rubber, Prolux 352 or approved alternative, to a
minimum dry film thickness of 75 microns and tinted to a shade just lighter than the
finishing colour with a suitable tinting agent which shall be compatible with the paint.

PA.15.5.4

Finishing:
Apply one coat of Kemrist Chlorinated rubber enamel (Prolux 351 or similar approved) to
a minimum dry film thickness of 35 microns.
The total dry thickness for the coating system shall not be less than 135 microns.

PA.15.6

PAINTING OF CHEQUER PLATE OR OPEN GRATING FLOORING AND

SUPPORTING FRAMES WITH EPOXY TAR SYSTEM
This paint shall apply to steel flooring, chequer plate and open grating flooring.

PA.15.6.1

Surface Preparation:
Surfaces shall be abrasive blast-cleaned to an SA 2 finish to Swedish Standard SIS
05/59/100 or acid pickled and passivated.

PA.15.6.2

Finishing:
Three equal coats of approved Epoxy Tar to SABS 801, Type II, shall be applied.
Consecutive coats shall be in distinguishing colours.
The total dry thickness for the painting system shall not be less than 105 microns.

PA.15.7

PROTECTION OF UNPAINTED SURFACES :

PA.15.7.1

Bright Machined Parts:

All bright machined parts shall have a protective treatment applied by the manufacturer
before despatch and this treatment shall be kept intact up to the time of handover unless
it has to be removed for installation. If the surface is exposed after installation a further
protective coating shall be applied in accordance with the manufacturer's requirements.

PA.15.7.2

Non-ferrous:
All exposed copper piping shall be cleaned down, degreased and all adhering materials
cleaned off without damage to the installation.

PA.15.8

FINAL INSPECTION
The Engineer may subject surface preparation and the completed paintwork to SABS or
other inspection; the findings of such inspection being binding on the Contractor. The
cost of such inspection will be borne by the Employer. In the event of workmanship
failing to meet the requirements of the Specification, the cost of the inspection shall be
borne by the Contractor.

23065

SS13

PA.16.

ELECTRIC MOTORS

PA.16.1

Fixed Speed Motors for Non-Hazardous Areas:

PA.16.1.1

The motor shall comply with the information stated on the data sheet.

PA.16.1.2

The motor shall be of cast iron frame, totally enclosed fan cooled, three phase with an
IP55 degree of protection and a chemical works finish. The paint colour shall be Mid
Brunswick Green, Number 226 to BS 381 C.

PA.16.1.3

Terminal boxes shall be provided with purpose drilled and tapped holes to suit cable
glands manufactured to BS 6121 : 1973, a knock out is not acceptable. The tapped
holes shall be fitted with plugs (with a screw driver slot to facilitate removal) for transit.
The holes shall be at the bottom of the box for horizontal shaft motors.
Terminal boxes shall be manufactured in cast iron or steel and arranged to suit the
enclosure, classification requirements. Plastic boxes and covers are not acceptable.
Terminal boxes shall be suitable for turning through 90 or 180 so that a side or top entry
is possible.

PA.16.1.4

Where specified the motors shall be fitted with Positive Temperature co-efficient (PTC)
thermistors for integration with the starter. The ends shall be brought out to terminals
located in the motor terminal box. Accordingly, the motor terminal box is to include a
dedicated suitable sized standard ISO thread to accommodate the glanding arrangement
for the thermistor cable.

PA.16.1.5

Provision shall be made for an earthing stud facility within the terminal box of the
machine, as well as the standard external frame earthing termination feature.

PA.16.1.6

Bearings shall be of ball or roller type and shall be packed with lithium base grease.

PA.16.1.7

All motors above 5,5 kW rating shall have six leads brought from the motor windings to
terminals in the terminal box complete with fitted copper links to make the motor suitable
for direct on line starting. All terminals and stator leads shall be clearly marked.

PA.16.1.8

Insulation of motors shall be to Class 'F' with Class 'B' temperature rise (80C).

PA.16.1.9

The Contractor must ensure that adequate torque is available to accelerate the drive to
full load speed for all types of starters, with a "run-up" time of (3 0.13 x kW) seconds.

PA.16.1.10

The starting torque when switched direct-on-line at rated voltage shall not be less than
150% full load torque.

PA.16.1.11

A stainless steel nameplate, stamped with the following information, shall be permanently
attached to the housing of the motor:
(i) Manufacturer's name and address
(ii) Volts/phase
(iii) kW rating
(iv) Full load current
(v) Manufacturer's model and serial number
(vi) Rated speed
(vii) Class of insulation and permissible temperature rise
(viii) Power factor
(ix) Motor windings configuration
(x) Frame size
(xi) Degree of protection.

23065

SS14

PA.16.2

On completion at the manufacturer's works the motors shall be subjected to Routine

Tests outlined in SABS 948 or BS.4999 as applicable. For motors with a rating of 125
kW and above, Type Tests shall be carried out on each batch of motors of the same
size.
A batch certificate, if not more than six (6) months old, will be acceptable.
If a full Type Test certificate is not available, then the manufacturer shall carry out a full Type
Test and Routine Test on one motor of each design for which a Type Test is not available.
No additional costs will be accepted for any factory tests.
Type test certificates will include the results of tests at rated voltage and frequency of the
following:
(i) Temperature rise
(ii) Momentary load
(iii) Efficiency at 50%, 75% and 100% full load
(iv) Power factor at 50%, 75% and 100% full load
(v) Starting torque (NM)
(vi) Starting current (A)
(vii) Light running current (A)
(viii) Noise level of dB(A) at one metre
(ix) Permissible acceleration time on starting up
(x) Area classification certificates by appropriate approving authority (if applicable)
After installation site tests should be performed at a voltage that is 80% of the appropriate
test voltage given in Table 24 of SABS 948. All test certificates for each motor shall be
submitted in triplicate to the Engineer.
NOTE: Factory test certificates shall be submitted to the Engineer prior to despatch of the
motors etc. from the factory.

PA.16.3

DATA TO BE SPECIFIED AND GUARANTEED BY THE CONTRACTOR

Any figure quoted in respect of full load output, torque output, efficiency, power factor and
temperature rise shall be subject to a guarantee.

PA.16.4

QUALITY ASSURANCE
The Contractor shall submit at the time of tender their standard works Quality Assurance
Programme stipulating the various stages of production and inhouse tests carried out during
the course of manufacture.

PA.16.5

PACKING

PA.16.5.1

The Contractor shall supply information on their standard packing techniques for the
equipment as per this enquiry at time of tender.

PA.16.5.2

The Contractor shall be totally responsible for the adequacy of the packing and protection
provided against climatic conditions, damage, and mishandling of the goods, during transit
from the works to the final delivery point, as indicated on the enquiry/order.

PA.16.6

MARKING

23065

SS15

PA.16.6.1

All packaged, bundled and loose items shall carry the Plant reference number (if
applicable), Contract number and project number.

PA.17.

COUPLINGS FOR POWER TRANSMISSION :

PA.17.1

COUPLINGS
Unless specified otherwise, all pumpsets shall be directly coupled (shaft to shaft) to the
drive motor by means of a flexible type coupling only. All couplings shall comprise of the
two cast iron flanges connected by means of a resilient, flexible component, the deflection
capability which shall be a prime design consideration. The flexible components shall also
be able to absorb transient peak loads and reduce vibrations and torsional oscillations on
the drive shafts.
All flexible couplings shall include for taper lock fixing and keys and keyways with top
clearance shall be allowed for on applications where load fluctuations are expected.
The flexible component shall be manufactured from neoprene rubber compounds suitable
for operating temperatures up to 70C and be resistant to oil and grease contamination.
All flexible couplings shall be able to accommodate the following incidental misalignments
or displacements :
Parallel or axial
Angular
Shaft end float

up to ,0 mm
up to 4,0
up to 8,0 mm

All flexible couplings shall be easily removable by withdrawal towards the individual shaft
stub ends. Couplings shall be sized and selected with due consideration for the maximum
power transmitted, shaft speed, the type of driven machine, the type of driving unit,
diameters of connecting shafts and the operational hours per day.
Where pump drive shafts require withdrawal for maintenance purposes, spacer couplings of
adequate dimensions shall be provided or allowed for as necessary unless specifically
excluded.
All keys and keyways and taper pins shall conform to BS 46 : Part 1 : 1958 (as amended).
Limits & tolerances for shafts and holes shall conform to BS 1916.
PA.18

ERECTION AND INSTALLATION :

PA.18.1

GENERAL :

PA.18.1.1

The construction of the pumpset and/or motor plinths, of the pipe ducts and cable
trenches/drainage ducts as necessary will be carried out under the Civil aspects of the
Contract generally but not always wholly in advance of erection of the Plant and equipment
to be supplied under this Contract. Holes should be left in walls and foundations whenever
practicable to accommodate pipes, foundation bolts and other equipment to be erected
under this Contract.

PA.18.1.2

It shall be the responsibility under the Mechanical and Electrical Portions of this Contract to
supply and set in position any steel columns and wedges forming a permanent part of the
works to support pipework, valves and equipment and to install and align any puddle pipes.
Excavation and backfilling of pipe trenches and casting of concrete anchor blocks and piers
to pipework and the grouting or concreting of pipes etc., will be measured and carried out
under the Civil Engineering aspects of the Contract

23065

SS16

PA.18.1.3

It shall be the responsibility under the Mechanical and Electrical Portions of this Contract to
provide the necessary specials, pipe fittings, joints, pipework supports etc. and manifold for
the connection of suction pipework, manifolds and delivery pipework to the new discharge
pipework for the operation of the plant provided.

PA.18.2

PROGRAMME OF WORK :

PA.18.2.1

In carrying out erection, the Contractor shall conform to his approved erection programme
unless otherwise agreed with and approved by the Engineer.

PA.18.2.2

The Employer may, from time to time, by order in writing, without in any way vitiating the
Contract, require the Contractor to proceed with the installation of the Works in such order
as in his opinion may be necessary.

PA.18.3

ERECTION, ADJUSTMENT, OPERATION, COMMISSIONING & TESTING :

PA.18.3.1

The Contractor shall make his own arrangements for handling and transporting all material
to and on the Site in a proper and careful manner to avoid damage, and shall be
responsible for properly storing and protecting all plant and equipment against damage by
water, weather, fire and any other interference before and during erection. In particular, the
Contractor shall ensure that all necessary precautions are taken to obviate the possibility of
motors being damaged by water.

PA.18.3.2

This Contract is to include for the erection, adjustment, putting into proper working order,
testing and maintaining of all plant, equipment and materials supplied or refurbished by the
Contractor. The erection of the plant is to be carried out by skilled and experienced erectors
and the plant, when erected, is to be of neat and workmanlike appearance, solidly and
evenly supported, true to line and level, plumb and in proper working order. The erection is
to include for the proper lining up of all bolts, pipes, pipework supports, fittings in holes left
by the Civil Engineering Contractor for the reception of the equipment and pipes; positive
support for such bolts, pipes and fittings shall be provided to avoid any movement of them
during concreting operations.

PA.18.3.3

On completion of erection, installation, unless otherwise specified, the Contractor is to clean

all exposed metalwork, polish parts to be left bright and paint all other parts, as specified
elsewhere. All motors, pumps, baseplates, valves, pipework, etc., shall be painted in a
colour as instructed by the Engineer.

PA.18.3.4

The Contractor is to finish off neatly all grouting and pointing carried out by him, and is
generally to leave all his work under the Contract clean, neat, tidy and in efficient working
order.

PA.18.3.5

After completion of erection and after completion by others of electrical work and having put
all equipment into proper adjustment and working order, the Contractor shall operate his
plant for at least 72 hours or such longer time as may be necessary for the purpose of the
witnessing of performance tests on site and of commissioning of the plant; the water and
electricity for the latter purposes will be provided free of charge by the Employer.

PA.18.3.6

Before handing over the plant, the Contractor is to ensure that every part of the equipment
is operating satisfactorily. The Contract will not be deemed to be completed for Taking Over
purposes until the Engineer is fully satisfied in this regard.

PA.18.3.7

In the event of the Contractor being unable to complete the installations or adjust and test
the plant and equipment at the time of installation through circumstances beyond his
control, it may be necessary for him to return to site at a later date to undertake this work.
Items have been provided in an annexure to the Schedule of Quantities/Prices to cover the
cost of returning to site, if ordered by the Employer to do so.

23065

SS17

PA.18.4.

OPERATING INSTRUCTIONS :

PA.18.4.1

Operating and maintenance instructions, hereinafter referred to as Instructions, are required

for all plant and equipment supplied and/or installed under this Contract. Such Instructions
shall be prepared and supplied against the item included in the Schedule of Prices.
Triplicate copies of Instructions shall be prepared and supplied by the Contractor.

PA.18.4.2

The Instructions shall be made up in the form of books with a rear pocket enclosing prints of
all the "As-built" Drawings relevant to the Mechanical and Electrical Portions of the
Contract.

PA.18.4.3

The Instructions are to be prepared by the Contractor and three copies are to be delivered
to ZAI Consultants CC, 892 Umgeni Road, Durban, 4000, two weeks before the
commissioning of the plant and equipment. ZAI Consultants CC will send one copy to the
Employer and one is to be kept at the Works.

PA.18.4.4

On the cover of each set of Instructions, the following information shall be indelibly printed
in bold lettering :
DEPARTMENT OF PUBLIC WORKS
CONTRACT NO WCS : WIMS002879
OPERATING AND MAINTENANCE INSTRUCTIONS FOR THE
FIRE PUMPS AT THE NEW LABOUR AND NEO-NATAL WARDS
__________________________________________________________
(Print name, address and telephone number of Contractor)
The first page of each set of Instructions shall be an index to the Instructions and shall
include a list of the numbers and descriptions of all drawings and pamphlets included in the
set.

PA.18.4.5

The Instructions shall be carefully prepared so as to provide in detail and with clarity a
complete description of all components of the plant and equipment and all information and
drawings required to give complete guidance to operators and maintenance staff on all
matters relating to the proper and safe operation and maintenance of the plant and
equipment and on all matters relating to the future ordering of spare parts which may be
required for maintenance purposes.

PA.18.4.6

Inter alia, the Instructions shall include the following :(a) List of spare parts supplied under the Contract.
This list shall include the full details referred to in the Contract relating to pump and
motor spares and similar full details relating to valve and control equipment. The
Engineer on behalf of the Employer reserves the right to accept or reject all or part of
the list provided by the Contractor at the time of tender and accept only the spares that
are considered essential.
(b) List of spare parts which are not supplied under the Contract but which may be
required for future major overhaul of mechanical plant and motor equipment.
(c) List of "name plate data" giving full particulars of serial numbers and other descriptive
data pertaining to the plant and equipment installed.
(d) List of points requiring lubrication and frequency of lubrication, stating for each point
the type and grade of lubricant recommended and full details as to quantity, the period
of time after which the lubricant is to be renewed and the manner in which it is to be
carried out.

23065

SS18

(e) Particulars of bearings, contacts and other moving parts with instructions relating to
any special attention which may be required.
(f)

Precautions to be taken in starting, running and stopping the plant or equipment.

(g) Routine tests which the supplier would suggest be carried out on the plant to ensure
that it is kept in good repair.
(h) Drawings depicting:
(i)

All dimensions as installed of pumps, motors, couplings, guards, bedplates and

connecting pipework, valves, specials etc.

(ii) Copies of all pump test sheets and characteristic curves.

(iii) Manufacturers' pamphlets and catalogues edited and clearly marked so as to
describe the particular equipment and plant supplied under the Contract.
(NOTE:

Pamphlets and printed catalogue data shall be bound into the Instructions
rather than pocketed with the drawings and all information in such
pamphlets and catalogues which is relevant to this Contract shall be clearly
marked.)

PA.18.5

INSTRUCTING OPERATORS DURING INITIAL PERIOD OF OPERATION :

PA.18.5.1

Experienced representatives of the Contractor and, where applicable, of all the Subcontractors shall attend the commissioning and performance testing of all equipment and
shall explain in detail and demonstrate, to the Employer's staff and operators, the contents
of the Instructions referred to above and the correct methods of operating and maintaining
the plant and equipment. The prices and rates tendered will be deemed to include
allowances for such explanation and demonstration as may be required to be provided by
the Contractor to ensure that the operating staff is fully informed as to how the plant and
equipment is to be cared for, operated, maintained and safeguarded. The Contractor shall
be solely responsible for filling with the recommended oil all gearboxes and other apparatus
and for lubricating all bearings and components before commissioning performance testing
or demonstrations.

PA.19

DETAILED SPECIFICATION :

PA.19.1

GENERAL :

PA.19.1.1

The Contractor shall guarantee and shall be deemed to guarantee that all plant and
equipment supplied under this Contract shall be capable of meeting the performance as
specified or otherwise approved under the Contract when operating under the required
conditions.

PA.19.1.2

The Contractor shall be required to perform the necessary tests to demonstrate that the
capacity of any item of plant or equipment meets that specified. The cost of such tests and
any necessary re-tests shall be borne by the Contractor. Wherever equipment or materials
are specified as being to approval then the Contractor shall be responsible for obtaining
such approval from the Engineer.

PA.19.2.1

SCOPE OF WORK :

23065

SS19

PA.19.2.1

As specified elsewhere in this document the Contractor shall supply, provide interim storage
as necessary, deliver and install, albeit as appropriate when the programme of the Civil
Engineering aspects of this Contract permits, (such programme having been drawn up by
the Contractor with the approval of the Employer) and then test, commission and maintain
the pumpset, associated pipework, valves, etc. all as specified herein, or approved under
the Contract. The pump set being required to deliver at the proposed rate of approximately
72,0 m/hr (20 l/s) against the dynamic head for one pump of approximately 33,0m water
gauge.

PA.19.2.2

In relation to the foregoing the Contract shall include and the prices shall be deemed to
include inter alia for :

PA.19.2.2.1

All pump units as scheduled or otherwise approved including electric drive motors,
baseplates, couplings, pressure gauges, gland drains, guards, packers and holding down
bolts including the levelling and grouting up of baseplates and holding down foundation
bolts, valves, special fitting supports as required by the manufacturer but not including the
construction of necessary thrust blocks and pipe support blocks, although details of such
blocks and supports shall be provided for the approval of the Employer.

PA.19.2.2.2

All pipework, specials, fittings, joints, valves as scheduled or otherwise approved including
pipe brackets/supports, straps and holding down bolts.

PA.19.2.2.3

All the necessary externally mounted no-flow switches, pressure switches and cabling
within the pump station, temperature switches, pressure gauges, required for the effective
operation of the pumpsets and control equipment.

PA.19.2.2.4

All the necessary electrical starter panels for all pumpsets and associated electrics.
Refer particular specification PB : Standard Specifications for LV Switchboards, Distribution
Boards and Motor Control Centres for the supply, installation, testing and commissioning of
the MCC for this contract.
The minimum international protection rating of IP 40 (internal) or IP 56 (external) shall be
applied.
Switchboards, distribution boards and motor control centres shall be designed,
manufactured and installed in strict compliance with SANS 10142 regarding type testing /
self certification depending on kA rating.
The enclosure shall be manufactured of 3CR12 stainless steel. The enclosure shall be
epoxy powder coated (colour orange). For recommended manufacturers refer Standard
Specification PB.17.
Each enclosure shall be provided with the following :

23065

1.

Lockable main isolator.

2.

Contractor, overload combination for DOL starting, up to 7,5kW, star delta starting or
other approved method for motors above 7,5kW.

3.

Voltmeter

4.

Pump selector switch.

5.

A hand / off / auto selector switch (Safety and overload devices must be functional in
the hand mode.

6.

One 15 Amp single phase 230 volt switch socket and waterproof light supplied through
a 30 mA earth leakage unit and separate distribution board.
SS20

Each pump shall be provided with the following instruments and indicator lights:1.
2.
3.
4.
5.
6.
7.

Sub isolation.
Ammeter (not less than 75mm dial diameter).
Hours-run meter with 5 digit non-resettable run hour meter.
Pump start button
Pump stop button
Overload re-set button
LED indicating lights for:
a) Mains power ON green
b) To show which pump is ON DUTY blue
c) To show when pump is RUNNING green
d) To show when pump has FAILED DUE TO OVERLOAD for each pump amber
e) To show when pump EARTH LEAKAGE HAS TRIPPED OUT - amber

8.

Earth leakage protection for non-submersible water pumps in terms of SANS10142.

Line monitoring relay for motors exceeding 7,5kW (single phase voltage, under
voltage, over voltage and phase failure protection)......................................

9.

Line monitoring relay for motors exceeding 7,5kW (single phase voltage, under
voltage, over voltage and phase failure protection)......................................

10. Transfer switch for future emergency generator.

The system operation, control, safety and alarms as required shall be as
specified in the ASIB Rules

PA.19.2.2.5

All painting and necessary corrosion and weather protection to the equipment and pipework
installations.

PA.19.2.2.6

All special tools and equipment required for the normal operation and maintenance of the
plant and equipment including the lubricants and grease required for the first filling of all
plant and equipment and for 3 months operation of the plant and equipment.

PA.19.2.2.7

The provision of "Instructions" as specified elsewhere.

PA.19.3

WATER QUALITY :

PA.19.3.1

The water obtained to be pumped is treated water.

PA.19.4

OUTLINE DESIGN PARAMETERS :

PA.19.4.1

Altitude of pump station

PA.19.4.2

Ambient Temperature :
Summer Max. at 12h00 + 40C
Winter
Min. at 06h00 + 3C

PA.19.4.3

Plant Operation :
One duty pumpset alternating with the standby pump

PA.19.4.4

The motor shall be suitable for a coastal environment and every allowance must be made
for corrosion protection.

23065

81 m above MSL

SS21

PA.19.4.5

Incoming Electrical Supply

(Supply Authority)

400 volt ( 10%) 3 phase, 4 wire

50 Hz ( 1%)

PA.19.4.6

Future emergency generator supply

PA.19.5

LUBRICATION :

PA.19.5.1

The Contractor shall be responsible for filling all gearboxes and lubricating all bearings to
the manufacturer's requirements initially and before commissioning.

PA.19.5.2

The pump and shaft bearings shall be provided with a separate pre-lubrication system.

PA.19.5.3

All grease used shall be free of acid and resin and should not tend to harden or crumble.
Greases of differing characteristics shall not be mixed. The grease for bearing lubrication
shall have a drop point of 160C.

PA.19.6

PIPEWORK, VALVES, COUPLINGS, ETC. :

All pipework, valves, couplings, flanges, bolts, nuts, joints provided under this aspect of the
Contract shall be in accordance with that Specified under Clauses PE.2 to PE.23 inclusive,
Materials and Workmanship of this Specification and shall be, to the appropriate Grade or
Class indicated in the Schedule of Pipes, Valves and Fittings so as to be capable of
withstanding the pressures that will be developed under operating conditions and in the
event of emergency stoppages without the operation of any surge attenuation facilities.

PA.19.7

PAINTING :
The Contractor shall allow for all necessary painting of all pumping equipment, motors,
pipework, valves, fittings, etc, included in this Contract both internally and externally. All
such paintwork shall be of an epoxy enamel finish externally and Copon shall be used for
internal lining of pipework unless otherwise indicated on the drawings or specified. The
paint and painting system shall be in accordance with that required for highly corrosive
conditions.

PA.19.8

SPARES :
Under the heading spares shall be included sufficient lubricants and grease for three
months operation of the plant and equipment.

PA.19.9

TESTING :
The prices entered in the Schedule of Quantities/Prices shall and shall be deemed to
include for all necessary factory and site testing and the provision of all necessary
equipment and labour including test pumps, connections, gauges, blank flanges, thrust
blocks, supports, the isolation of apparatus, where necessary from the applied pressures
and for making good defects unless otherwise specified.

PA.19.9.1

Pump - Factory Tests:

The pumps shall be subjected to the specified hydraulic pressure test which will be to a
pressure equal to one and a half times the maximum head the pump will generate at noflow or to the maximum surge pressure which will obtain whichever is the greater.
Each pump set shall be subjected to performance tests in accordance with BS 5316 at the
manufacturer's works or in approved testing premises; which tests shall include as follows:

23065

SS22

(a) the pumpsets shall be tested at sufficient points to define the pump characteristics;
one point being as close to the duty point as practicable and one point closely on either
side of that point.
(b) In addition to the test report required after completion of the tests; the following curves
shall be certified and witnessed and submitted with comparisons of curves submitted at
the times of Tender to the Engineer in triplication before erection of the pumps on site:
(i)

Test Curve

Total Pumping Head (metre of water)

vs Discharge (m/hour)

(ii)

Test Curve

Pump Efficiency (%) vs Discharge (m/hour)

(iii)

Test Curve

Input Power (kW) vs Discharge (m/hour)

(iv)

Test Curve

Amps per phase vs Discharge (m/hour)

(NOTE:

The above test curves shall be calculated on the basis of the pump
tests in conjunction with the results of simultaneous or separate
tests on the appropriate motor without allowance being made for
power factor correction capacitors which shall be installed and
assuming a 380V, 50HZ, power supply).

If the performance of any of the pumpsets is outside the limits of tolerance the Contractor
shall rectify the fault or shall provide a new pumpset for testing. Alternatively, the Engineer
may require the Contractor to supply the pumpset at a reduction in price determined by the
Engineer.
PA.19.9.2

Motor - Factory Tests:

Routine tests shall be carried out on motors in accordance with SABS Specification and
tests shall be carried out to prove the performance of the motors against the data sheets.
Copies of the certified tests shall be forwarded in triplicate to the Employer.

PA.19.9.3

Pumpsets - Performance Tests on Site:

By running the pumpset after commissioning the Contractor shall carry out sufficient
performance tests in the presence of the Employer, or his Representative, to verify that the
plant is operating satisfactorily in accordance with the Factory test certificates.
Because the rate of discharge may not be readily measurable on site the efficiencies of
pumps and motors need not necessarily be re-checked but the following performance tests
shall be carried out.
(NOTE: Speed and voltage shall be measured during such tests).
(i)

Closed delivery valve - check head developed by pump and current taken against
factory test curves (delivery no-flow limit switch de-activated for this test).

(ii) Maximum head developed.

(iii) Duty point - check head and motor current.
(iv) Delivery valve full open - check that power (kW) absorbed does not exceed full load
continuous current of motor.
(v) Check operation of the low pressure pump start switch and delivery no-flow cutoff switch.
PA.19.9.4
23065

Pipework - Pressure Testing on Site:

SS23

On completion of erection and at least seven days after all necessary pipework, supports,
struts and thrust blocks have been constructed, the pumps and interconnecting pipework
and valves shall be filled with water and tested to not less than one and a half times the
maximum operating pressure or to the surge pressure which could obtain whichever is the
greater.
PA.19.10.

PUMPING PLANT :

PA.19.10.1

Description
There shall be installed two new pump sets and one jockey pump in the basement of
the new ward. The new pump set bases to take the new pump sets will be provided
and constructed under this Contract by others.
The new pump sets inlet shall connect directly into a common 150mm NB suction
manifold attached to the wall.
The new pump sets out shall connect directly into a common 100mm NB delivery
manifold attached to the wall.
The flow velocity in the suction and discharge manifolds shall not exceed 1,5 m/s and
2,5 m/s respectfully.

PA.19.10.2

Pumps and Ancillaries :

PA.19.10.2.1 The pumps provided shall be of the self priming type or other approved alternative to suit
the pumphouse structural constraints and the configuration proposed for the suction and
delivery manifolds. The pump units shall comply with the duties identified in the
accompanying System Curve or approved duties. The efficiency of the pump should be as
high as possible at the system duty/operating point.
The speed of the pump should preferably be 1450 r.p.m. but should not exceed
2900 r.p.m. The pump is to be directly coupled to suitable squirrel cage induction motor.
The pump casing shall be manufactured from high grade cast iron or cast steel and shall be
properly designed and rigidly secured to a baseplate. The pump casing shall be tested to
the specified test pressures.
Impellers shall be manufactured from bronze, or other approved material.
The pump shaft shall be of high tensile stainless steel with protecting sleeves (where
applicable) of bronze or other suitable metal, the diameter being sufficient to withstand and
transmit without whip and with ample margin of safety all torsional and bending stresses to
which it may be subjected.
Bearings are to be of the selected heavy duty cylindrical roller type at the suction side and
angular contact ball bearings at the discharge ends. The bearings shall be accessible and
dustproof and waterproof with suitable provision for continuous lubrication, robust, freerunning, readily replaceable seals and corrosion resistant shaft sleeves shall be fitted to the
pump. Packed glands are preferred to mechanical seals.
All parts shall be of ample dimension and strength and hardness, free from flaws,
accurately machined, properly assembled and fitted so as to avoid the setting up of initial
stresses in construction or erection and to ensure perfectly free running.
The pump shall be provided and fitted with a suitable and adequate hydraulic balancing
device to absorb the unbalanced axial thrust of the rotating assembly. The device shall
consist of back vanes and balancing holes or equivalent and approved alternative.
23065

SS24

Provision must be made to protect the balancing device when operating at delivery
pressures below the pump manufacturer's recommendations. The balancing and counter
balancing discs shall be manufactured from hardened bronze and cast iron or approved
alternatives.
The pump housing tie bolts shall be of the high tensile steel type, sized for the duty of the
pump.
An air release valve, provided with a lead off pipe for waste water shall be fitted to the
uppermost point of the pump casing. A 12mm dia. drain valve and drain pipe shall be
provided on each pump and run to discharge. Gland water collectors together with pipes to
drain therefrom shall be provided.
Each pump is to be fully equipped with all necessary air cocks for removal of air together
with suitable copper bleed pipes. An airbleed cock and drain pipe shall also be provided at
high points on the delivery mains.
Pressure gauges shall conform to BS 1780 wall-mounted concentric scale industrial type
150mm dial diameter, graduated in kilopascals. Each gauge to register at approximately
50% of full scale reading during normal operation.

The suction and delivery pressure gauges for each pump shall be rigidly mounted on
a wall near to the pumps with all dials at the same elevation, and labelled as to which
pump and which pressure they apply.
Each gauge shall be equipped with a bronze isolating cock and detachable porous metal
damper of approved design and connected to the pipework by means of copper tubing
neatly laid and securely fixed.
The prices for all pump accessories and gauges shall include and shall be deemed to
include allowances to cover the cost of everything, such as brackets and fixings, necessary
for setting up this part of the plant in a neat and workmanlike fashion, all so arranged as to
facilitate reading of gauges and clearing of drainage tubing without dismantling.

PA.19.10.2.2 Drive Motor:

The pump shall be driven by a vertical or horizontal T.E.F.C. squirrel cage induction, 4 pole
380V, 50 Hz, 3 Ph 6 connection electric motor fitted with anti-condensation heaters and
facilities for motor temperature monitoring by an electronic motor protection unit. The pump
shaft is to be fitted with a flexible half coupling complete with pins and bushes, the bushes
are to be of the cone ring type.
The thrust assembly shall cater for both the thrust conditions of the pump and none of that
thrust transmitted shall be imposed on the electric motor.
The motors shall be suitable for direct on line starting against the full system hydraulic
pressure. The motor shall be adequately sized to the approval of the Employer, to be nonoverloading and shall have a continuous rating of at least 15% above the pump input power
at the duty point.
The motors shall be suitable for continuous operation at the altitude of the treatment works
level and at the ambient temperatures. Motors shall be designed in accordance with the
requirements of BS 5000. Part 99 or SABS, similar for a full load speed not exceeding
3000 r.p.m.
23065

SS25

Motor windings shall be thoroughly moisture-resistant and insulated in accordance with BS

2757 or similar for Class F insulating materials. Maximum temperature rise above the
ambient temperature shall be limited to 80C.
Motors shall be provided with approved terminal boxes and glands of ample dimensions to
accommodate the cables to be connected to them by the Contractor.
An approved earthing terminal shall be provided on the frame of each motor so that each
machine may be earthed in accordance with local regulations by the Contractor.
On completion in the manufacturer's works the motors shall be subjected to high voltage
tests in accordance with the requirements of BS 5000 Part 99. In addition routine tests as
laid down by BS 5000 Part 99, shall be carried out and test certificates in triplicate giving
records of all such tests shall be submitted for approval before delivery to site is
undertaken. After installation on site the necessary high voltage test shall be carried out.
PA.19.10.2.3 Drive Coupling:
The coupling will be of the positive transmission type with sufficient resilience to absorb
starting torque and shock. It shall be possible to remove and replace the motor drive from
the pump unit without removal of motor/pump half couplings from their respective shafts.
The coupling will be installed complete with a suitable guard as approved by the Employer.
PA.19.10.2.4 Pump Operating Controls :
(a) "No-Flow" Protection:
A paddle type no-flow switch shall be installed on the delivery pipe of each pump. A
timer is to be installed in the switchboard to prevent the pump from running more than
one minute if there is no flow from its individual outlet. The flow switch, connection
points and the interconnecting cable are to be provided under this Contract.

(b) Pressure switch

A pressure switch shall be mounted on the delivery pipe. The pressure switch
will cause the duty pump to start on detection of low pressure caused by a fire
hydrant coming into operation.

23065

SS26

SECTION PB
STANDARD SPECIFICATION FOR LV SWITCHBOARDS,
DISTRIBUTION BOARDS & MOTOR CONTROL CENTRES
PB.1

SCOPE OF WORK
This specification covers the supply, installation, testing and commissioning of low voltage
switchboards, distribution boards and motor control centres, for use at phase to phase voltages
up to 600 V.

PB.2

GENERAL

PB.2.1

Everything necessary
The supply and installation of plant or equipment required by adherence to the following Act and
Regulation may not have been further detailed in other parts of the specification, but shall
nevertheless be considered as forming part of the contract. The installation should include
everything necessary and installed to the approval of the Employer.

PB.2.2

Standards
The equipment shall be designed, manufactured, tested and installed in accordance with the
requirements of the latest edition of:
(a)

The Occupational Health and Safety Act 85 of 1993 and subsequent amendments and
regulations issued thereunder.

(b)

South African Bureau of Standards Specification SABS IEC 60044; 60439/1; 60947/4;
61643/1

(c)

South African Bureau of Standards Code of Practice SANS 10142.

(d)

South African Bureau of Standards Specification SABS 152, 156, 172, 1222, 1195, 1473,
1474, 1765.

(e)

South African Bureau of Standards Compulsory Specification SABS VC 8003, 8036.

(f)

British Standard Institution BS 1433, 159, 5486.

The equipment shall in addition comply with the following requirements which shall supersede
the provisions of the above specification in the event of differing requirements.
PB.3

SHEET METAL ENCLOSURES

PB.3.1

General

PB.3.1.1

Sheet metal enclosures for switchboards, distribution boards and motor control panels shall
be wall or floor mounting as indicated on the drawings or described in the Detailed or
Standard Specification.

PB.3.1.2

In general, the enclosure is to be fabricated from a welded steel frame, to which the doors
and other covers are to be fitted. The use of pop rivets in any of the frame construction is not
permitted.

PB.3.1.3

All welds are to be ground smooth and all external voids to be filled.

23065

SS27

PB.3.1.4

Lap welding of panels and boxing of sections shall be avoided in the construction to obviate
corrosion of the unpainted surfaces and facilitate the cleaning of the boards. Bolted stiffening
channels and braces are acceptable.

PB.3.1.5

Completed sheet metal enclosures shall be free internally and externally from burrs, sharp
edges and blemishes. The metal enclosures shall be dust- and verminproof throughout and
constructed to meet ambient conditions. A removable steel base frame shall be allowed for
floor mounting boards and be constructed of at least 3 mm channel with a clearance of at
least 100 mm above the floor. Removable lifting eyes shall be provided for heavy panels.

PB.3.1.6

The sheet metal enclosures shall be designed to accommodate the electrical distribution and
control equipment shown in the diagrams and comply with the constructional requirements of
this specification.

PB.3.1.7

The construction of the LV switchboard enclosures shall allow for the board to be extended
on both sides by the addition of panels without the need of cutting openings for busbars.

PB.3.1.8

Bolts, nuts and washers used throughout shall be suitably plated to prevent corrosion,
preferably cadmium plated with the exception of busbar bolts, which shall be of high tensile
steel.

PB.3.1.9

Screwed knobs used for securing doors or hinged covers shall be provided with retaining
washers to prevent the screwed knob falling out when the door or cover is opened.

PB.3.1.10

The use of self-tapping screws is unacceptable (except for the securing of labels). The use
of double sided or "mirror" tape or self adhesive components for the fixing of any equipment
is not acceptable.

PB.3.1.11

All equipment, covers, wireways and ducting shall be bolted to the enclosure with threaded
rod or welded bolt. No loose nuts are acceptable. All tapped holes in metal work shall have
a minimum tapped thread length equal to the diameter of the tapped hole and the exposed
metal work shall be protected against corrosion by the application of a suitable inhibitor over
the tapped area.

PB.3.2

Mild Steel

PB.3.2.1

Unless otherwise specified, the metal enclosures, internal panels and all equipment support
frames shall be manufactured from "Zintex" steel plate. When required, glass panels may be
specified for viewing indication equipment.

PB.3.2.2

The minimum thickness of the "Zintex" sheets used shall be 1,6 mm for panels not
exceeding 0,5 m or 2 mm for larger panels. Thicker sheets shall be used for very large
panels and where the weight of the equipment would cause buckling or vibration.

PB.3.2.3

All metal used for the fabrication of the board, i.e. internally and externally, shall be painted.
The steel plates and extrusions used in the fabrication shall be thoroughly de-scaled and
de-greased on completion of the manufacturing operations and treated with a corrosion
inhibiting process before painting.

PB.3.2.4

The corrosion inhibiting process shall be suitable for the environmental conditions to be
encountered on site and full details shall be provided at the time of tendering. Details of the
chemical process employed and the method of application shall also be provided at the time
of tendering.
As a minimum requirement, the painting process shall consist of the following:
(a)

23065

De-grease and clean metal with trichloroethylene.

SS28

PB.4

(b)

Apply two-pack wet primer Plascon EPB 661 (base) with EPB 325
(catalyst) to 15 microns, allow to air dry for 30 minutes and low bake in
oven at 80C to 100C for 20 minutes. Alternatively, allow primer to air dry
for 24 hours. Should primer require thinning, use Plascon TH 127 solvent.

(c)

Apply epoxy polyester powder coating with electrostatic gun to thickness

40 microns minimum and 80 microns maximum and bake in oven at 180C
for 12 minutes. Final colour to be Plascon DPF 191 Orange (BSS 557) or
unless otherwise indicated on the drawings.

PROTECTION CLASS

PB.4.1

The protection class for the assembly as a whole shall be with all covers in place and all
doors secure and locked.

PB.4.2

The minimum protection class of the assembly shall be as follows unless otherwise
specified :

PB.4.2.1

If the assembly is installed outdoors and subject to rain then the class shall be IP53.

PB.4.2.2

The protection between the cable and feeder compartments in Form 3 or 4 assemblies is to
be provided by means of neoprene grommets or Tufnol sheets cut to fit around the
conductors.

PB.4.2.3

If the assembly is wall mounted, surface or flush, where switch toggles protrude and the
assembly is installed in a clean area for example an office then the enclosure class shall be
IP 40.

PB.4.2.4

Any ventilation louvres are to be fitted with a 1 mm anti-vermin mesh.

PB.5

HINGES, LOCKS AND ACCESSORIES

PB.5.1

Hinges and door handles shall be manufactured from non-ferrous materials, suitably finished
and treated against corrosion by an electro-plating process.
Pewter components or
insufficiently resilient materials will be rejected.

PB.5.2

Hinges and door locks of the weld-on type will not be acceptable. "Piano" type hinges are also
not acceptable.

PB.5.3

Hinges and door locks shall be well designed to ensure satisfactory operation and a pleasant
appearance.

PB.5.4

The repeated opening and closing of the hinged panels or the operation of the door locks shall
not cause chipping or scratching of the painted surfaces or other blemishes to the finished
boards.

PB.5.5

Key operated, lockable door handles shall be 6 mm square drive locks and fitted only if
specifically requested. In general, door latches which may be operated by electrician's tools
such as screwdrivers and panel keys, are preferred to those requiring special keys or handles,
which may be removed or lost. All doors must be fitted with a handle.

PB.5.6

All doors shall be fitted with "Barker and Nelson" or other equipment type door locks with a 180
movement or otherwise approved.

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SS29

PB.5.7

Door latching and de-latching operations shall be smooth and quick, whilst ensuring proper
compression of the sealing gaskets without damaging or marking the paintwork or
corrosion-resistant surface of the board.

PB.5.8

Sealing strips and gaskets shall be made of durable, non-hardening rubber, neoprene or other
synthetic material. Care must be taken to ensure that even pressure is exerted along the entire
length of the gasket and that neither deflection or buckling of panel occurs when the gasket is
compressed.

PB.5.9

To avoid damage to the paintwork, screws, bolts, door locks, etc., must not be in direct contact
with painted surfaces.

PB.6

ASSEMBLIES

PB.6.1

Switchboards

PB.6.1.1

Switchboards are defined as assemblies which are floor standing, except where the circuits
are predominately single phase and the designed fault level is not more than 10 kA, in which
case the assembly is classed as a distribution board.

PB.6.1.2

Switchboards shall consist of a sheet steel enclosure, free standing on a supporting base
frame. The base frame shall be provided with pre-drilled holes for fixing the board to the
floor. Conduit and cable entries shall be provided on the top and bottom panels and front
and/or rear access shall be provided, as indicated on the drawings.

PB.6.1.3

Busbars shall be installed at the top or bottom of the board and along its full length. Busbar
droppers shall be provided either behind or alongside the feeder cubicles as specified
elsewhere.

PB.6.1.4

The incoming main switch shall be mounted in its own cubicle, be easily accessible at all
times and shall be easily distinguishable from the other switchgear.

PB.6.1.5

The distribution equipment installed within the board (i.e. ACB, CFS or MCB), shall be
mounted in vertical parallel rows unless the arrangement calls for the horizontal placing of the
equipment and provided the equipment manufacturer warrants operation in this direction.

PB.6.1.6

Large withdrawable air circuit breakers and switch fuse units shall not be positioned at high
level unless facilities are provided to assist maintenance staff in withdrawing these units.

PB.6.1.7

The arrangement shall be such that ample space exists between adjacent items of
equipment for the installation of incoming and outgoing conductors and the expansion of the
ionised gas generated during circuit interruption.

PB.6.1.8

The incoming busbars to the board's main switch shall be either heat shrunk PVC insulated
or covered with a removable insulated barrier. All live parts must be protected to IP 30
irrespective of the form of separation. Where applicable, the incoming isolator is to be fitted
with a shroud over the incoming terminals.

PB.6.1.9

Flash barriers shall be interposed between items of equipment which, by virtue of their design
or arrangement in the board, are likely to cause the breakdown of the di-electric insulation to
adjacent items of equipment during operation.

PB.6.1.10

The board shall be of sufficient dimensions to allow the installation of all equipment specified
and any future equipment indicated on the drawings without unduly restricting the access to
and the clearance between the various items.

PB.6.1.11Particular attention shall be paid to the accommodation and bending of incoming and outgoing
conductors within the enclosure and the working space necessary for making off the cables,

23065

SS30

installing the lugs and connecting into the equipment. Suitable provision shall be made for
verminproofing the cable entries and earthing the armouring.
PB.6.1.12

Any part of the distribution board metalwork shall be electrically continuous and a suitable
earth bar shall be provided for the earthing of the enclosure. Particular attention shall be paid
to the earth continuity of removable and hinged access panels, particularly those carrying
supervisory and control equipment. Flexible copper straps may be used for the purpose of
ensuring the earth continuity between the board and the panels.

PB.6.1.13

The minimum form of separation as depicted in SABS IEC 439 Part 1, shall be Form 2 in
which the busbars are separated from the functional units and from the feeder outgoing
terminals. Components within a functional unit, which may consist of a number of feeders,
are not required to be separated.

PB.6.1.14

In the case of Form 3 or 4 assemblies, the neutral bars need not be run through the feeder
compartments, but need only be provided in the cable compartment. The neutral busbar must
be clearly distinguishable from the earth busbar.

PB.6.1.15

In Form 3 or 4 assemblies the protective devices must be operated via door mounted
handles.

PB.6.1.16

Where busbar stubs are connected to protective devices to accommodate other equipment,
such as CT's, then these busbars must be supported on stand-off insulators near the cable
termination point. In the case of parallel connected outgoing cables, sufficient space must
also be provided on the busbar to permit a lug to be bolted to each side of the busbar.

PB.6.2

Distribution Boards

PB.6.2.1

Distribution boards are defined as assemblies which are wall mounted or which are floor
standing, in which case the outgoing circuits are predominately single phase and the
designed fault level of the board is not more than 10 kA.

PB.6.2.2

Distribution boards may be flush, semi- recessed or surface installed, as indicated on the
drawings. Conduit and cable entries shall be provided on the top and bottom panels.

PB.6.2.3

Distribution busbars which are pre-drilled and fully tinned and mounted on suitable stand-off
insulators shall be provided in all 3-phase boards. It is desirable that if busbars are not
installed within a sheet or expanded metal enclosure, then a clear perspex safety cover shall
be supplied to prevent accidental contact.

PB.6.2.4

All wall mounting boards, unless differently indicated on the drawings, shall be front access
only and shall be manufactured in two parts : a rear chassis, which is either built into or
attached to the supporting wall, and an outer panel secured to the chassis on completion of
the work and readily removable from it.

PB.6.2.5

The arrangement is sought in order that chassis may be supplied at an early stage, whilst
building and installation work are in progress, without the risk of damage to the outer panel or
equipment installed therein.

PB.6.2.6

The chassis shall be manufactured from galvanised mild steel plates, in order that they may
withstand the rough handling and dirty ambient conditions prevailing during construction.
Surface wall mounted panels may alternatively be supplied with chassis finished in Matt
Black.

PB.6.2.7

Chassis shall have suitable knockouts along the top and bottom panels for the terminations of
all conduits in not more than two rows. A feeder cable entry knockout shall also be provided,
suitable for the feeder cable rating indicated on the drawings.

PB.6.2.8

The outer panel, secured to the chassis by means of adjustable bolts, shall support the
equipment trays, the busbars and the wiring harness.

23065

SS31

PB.6.2.9

Single phase sections of three phase boards shall be arranged in three horizontal parallel
rows, directly above one another and in the phase sequence Red - White - Blue from top to
bottom.

PB.6.2.10

3-phase MCB's, where these are not used for sub-distribution, may be installed at the right
hand end of the single phase row. If more than three (3) 3-phase MCB's are required in any
DB (i.e. more than 1 per row) then a separate 3-phase section must be provided. These
arrangements are illustrated in the standard layout drawings.

PB.6.2.11Lighting and power circuits shall be separated by a blank space along the horizontal rows.
Extra space for future circuits shall be allowed for at the right hand side of each single phase
lighting and power row of equipment, in the ratio of one spare space for each four lighting or
power circuit installed. A minimum of one space shall be allowed to each lighting and power
row.
Dummy covers are to be provided over spare spaces. Similar provision for future circuits
shall be made on the busbars, neutral and earth bars.
PB.6.2.12

The phase, neutral and earth bars must be positioned so that it is possible to connect
additional circuits to the bars without having to remove any other equipment. The earth bar
must be bonded to the chassis and the incoming earth conductor must connect directly to the
earth bar.

PB.6.2.13

In the case of single phase DB's, the incoming isolator may be of the same type and size as
the rest of the MCB's in the DB. However, in the case of 3-phase DB's, the incoming isolator
must be of the large frame (MCCB) type, even if the outgoing feeders are small frame MCB's.
The large frame isolator must be fitted with a shroud over the incoming terminals.

PB.6.2.14

Any part of the distribution board metalwork shall be electrically continuous and a suitable
earth bar shall be provided for the earthing of the enclosure. Particular attention shall be paid
to the earth continuity of removable and hinged access panels, particularly those carrying
supervisory and control equipment.
Flexible copper straps may be used for the purpose of ensuring the earth continuity between
the board and the panels.

PB.6.2.15

PB.6.3

A removable escutcheon plate shall be provided, behind a hinged door, through which
toggles and other operating handles shall project. All wiring terminations and connections
shall be made behind the escutcheon and shall not be accessible without its prior removal.
The board shall be designed so that the switch toggles, instruments, etc., are easily
accessible to operators of average height (i.e. upper edge of equipment not higher than 2 m
or lower than 0,25 m above floor level), unless otherwise specified.

Special Requirements for Motor Control Centres

PB.6.3.1 Motor Control Centres (MCC's) are defined as assemblies where at least either 60% of the
feeders or 60% of the total load is devoted to motor drives.
PB.6.3.2 The general requirements of switchboards apply irrespective of whether the MCC is floor or
wall mounted.
PB.6.3.3 Unless otherwise specified, the form of separation shall be Form 4. Each motor drive is to be
considered a functional unit and is to be in its own compartment.
PB.6.3.4 The following will be the minimum provisions on each motor drive, unless otherwise specified :
All components must be in compliant with Type 2 co-ordination (IEC)
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SS32

(a)

Main protective device, either MCCB or CFS, as specified.

(b)

Control protective device either MCB or fuse, connected downstream of the main
protective device.

(c)

Door mounted interlocked operating handle with padlockable facility.

(d)

Contractor and overload relay / electronic motor protection relay.

(e)

Numbered outgoing connection terminals.

(f)

CT and instantaneous ammeter.

(g)

Earth leakage device with CT if specified.

(h)

Door mounted control devices :

Stop / Start push buttons.

Run / Stop / Trip indicator lights.
Overload reset.
Local / Remote switch, if specified.
Earth leakage test and reset.

PB.7

BUSBAR AND BUS CHAMBERS

PB.7.1

The busbars and their supports shall be :

(a) Electrically and mechanically designed to withstand the short circuit stresses which may
occur with the fault level specified for a period of not less than one second. (Attention of
tenderers and manufacturers is drawn to the requirement for type test results of the short
circuit capability of the busbars.)
(b) Of uniform cross-section throughout the busbar run.
(c) Manufactured from copper.
(d) Designed to accommodate expansion and deflection due to thermal and mechanical
stresses without damage or distortion occurring to the busbars or the equipment connected
to them.
(e) Shall comply with BSS 1433 and 159 and SABS 1473-2 and 1195, where applicable.

PB.7.2

Busbars on the incoming side of the main switch/breakers are to be insulated with heat shrink
sleeving with distinctive phase colours. The earth bar and busbar joints and cable terminations
must not be insulated.

PB.7.3

If the busbar is close to areas where cable terminations and connections are carried out whilst
the busbar is energised and if the busbar is not housed in a chamber then a clear perspex
safety cover shall be supplied.

PB.7.4

Busbar chamber covers to be bolted in the four corners and equispaced at least every 500 mm
around the periphery. Nuts welded to the cover frame may be used for fixing or the frame may
be tapped as specified. Loose or captive nuts may not be used.

PB.7.5

The construction of the enclosure shall allow for the extension on both sides by the addition of
panels without the need of cutting openings for busbars.

PB.7.6

Phase identification colours are to be fixed to the bars at regular intervals and shall be Red,
White & Blue (R-W-B) from top to bottom, from left to right, from back to front when facing the
front of the board, unless otherwise specified. Both main and secondary bars must be identified.

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SS33

PB.7.7

The minimum clearance between live conductors or live conductors and earth shall be 20 mm
for systems up to 600 V.

PB.7.8

Busbars shall be adequately and continuously rated for the specified current with a maximum
temperature rise of 40C relative to a peak ambient temperature of 40C giving a maximum
peak busbar temperature of 80C.
In the case of fault levels of 20 kA or higher, the manufacturer shall produce type test results of
the proposed busbar arrangement, in the enclosure intended, to prove the correct sizing of the
bars and that the temperature rise is within the limits specified.
In the absence of such type tests the following minimum criteria will be used in determining the
rating of rectangular bars with the larger side in a vertical plane :
Current rating of multiple bars relative to single bar rating :
2 bars
3 bars
4 bars

:
:
:

1,66
2,09
2,30

Derating of current carrying capacity within steel enclosure relative to free

air rating
:..................................................................................................0,68
Derating of capacity for 40C temperature rise instead of 50C :..................................0,88
In this case the ratings given in the publication "Copper for Busbars" by the Copper
Development Association are to be used.
PB.7.9

Neutral busbars in three phase, four wire, supplies shall have a cross-section of at least 50% of
the cross-section of the phase busbars and shall be pre-drilled.
Where multiple busbars are used per phase, the current rating of the neutral bar shall be at
least 50% of the rating of the phase bar combination.

PB.7.10 Earth bars are to be run the full length of the switchboard and must be continuous. The bar is to
be positioned near the gland plate top or bottom or both as necessary. Earth bars are to have
the following minimum cross-sectional area with a minimum thickness of 6,3 mm :
Specified Three Phase Symmetrical
Fault Level : (kA)
Up to and including
Above 5 and up to
Above 10 and up to
Above 20 and up to
Above 30 and up to
Above 40

5
10
20
30
40

Earth Bar Size

(sq.mm)
36
75
150
200
300
400

PB.7.11 In main switchboards, which derive a supply directly from a transformer, the neutral of the
transformer is to be bonded to earth at a point inside the switchboard.
This point of bonding shall be close to the point of entry of the incoming conductors into the
switchboard and is to be in a conspicuous place. The bonding conductor is to be at least of
the same area as the earth bar and is to be insulated in green or green/yellow PVC for
identification.

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SS34

PB.7.12 Incoming and outgoing connections from the busbars shall be designed for the specified fault
conditions and shall be rigidly supported by brackets to support their mass from the busbar
stack or the equipment terminals.
PB.7.13 Pinch screw terminals must not be used on any of the busbars. Terminals must be of the
clamping plate type or else the connections must be lugged and bolted.
PB.7.14 Main and subsidiary busbars shall be of the same material and all bolted joints shall be tinned
or silver plated. The joints shall be tightened to the correct bolt torque and shall be locked
into position to prevent connections becoming loose due to thermal cycling or mechanical
vibrations.
PB.7.15 Switchboards with incomers and/or bus-couplers shall be constructed so that the buscouplers are each in a segregated compartment and that the busbars associated with each
incomer are also segregated. The main and secondary busbar chambers must also be
segregated from each other. Furthermore, in long switchboards, the main busbar chamber is
to have segregating barriers provided at intervals of not more than 5 metres. The degree of
protection between the above busbar compartment is to be at least IP30.
PB.8

CABLING AND WIRING

PB.8.1

All wiring and cabling shall be carried out and be readily accessible from the front of the
enclosure unless otherwise stipulated.

PB.8.2

The requirements of SABS 0142 must be complied with.

PB.8.3

The minimum conductor area of any power circuit shall not be less than 1,5mm. Suitably
protected control circuits may be wired with no less than 1,0mm flexible conductors. 2,5mm
wiring shall be used for the secondary circuits of current transformers.

PB.8.4

If the current rating dictates that multiple flexible conductors are to be connected to a
protective device, then the conductors are to be connected to the device via stub busbars.

PB.8.5

The connections between the incoming supply and the busbars or between the busbars and
the incoming side of the outgoing power circuit protective devices, shall be made with
conductors having a fault capacity equal or higher than the fault level indicated for the board.
Flexible conductors may not be used to connect to the incoming side of the power circuit
protective devices at specified fault levels of 20 kA or higher, in which case only solid busbars
may be used.

PB.8.6

Control wiring connected to the main or secondary busbars shall be protected with HRC
fuses, preferably mounted directly on the busbars, but otherwise with no more than a 150 mm
long live conductor from the busbar. Unprotected wiring may not be run into a compartment of
a switchboard which is separated from the compartment in which the tap-off is made. In
general, where control supplies are obtained directly from the busbars, upstream of any
feeder protective devices, the instruments so supplied are to be protected via 2 fuses in series
with a collective 10 A busbar mounted fuse for all instruments and an individual 2 A fuse for
each instrument.

PB.8.7

Sub-distribution circuits protected by HRC fuses need only be rated for the maximum
prospective asymmetrical fault level possible when the largest fusible link is installed in the
fuse base.

PB.8.8

Multi-stranded conductors shall be used in preference to solid conductors. Solid conductors

may not be used for control wiring.

PB.8.9

Insulated conductors shall not be bunched in large numbers, to avoid heat accumulation
within the core of the bunch or damage to healthy circuits in the event of fault.

23065

SS35

PB.8.10 If bunching of conductors is unavoidable, the conductors should be de-rated in accordance

with the relevant table of the SABS Code of Practice for the Wiring of Premises.
PB.8.11

Conductors must be rated for an ambient temperature of at least 40C.

PB.8.12

The insulation of the conductor shall not be stripped beyond the leading edge of the terminal in
which it has to be accommodated. Stripping shall be carried out without damage to the
conductor, preferably by means of a cable stripper.

PB.8.13

All cable and wire ends to be terminated on bolted connections to have crimping lugs and
ferrules fitted and crimping shall be carried out using the proprietary tool. Hexagonal crimps
must be employed for conductors 4 sq.mm or larger. Cable & wire ends due for termination on
circuit breaker, contactor and non-lugged type terminations shall have the exposed copper
strands bound with copper wire to prevent splaying when the connection is tightened.

PB.8.14

The wiring shall be carried out neatly along perpendicular lines and it shall be accommodated
in enclosed wireways or trunking which upon completion of wiring shall have a 20% spare
capacity. The wireways are to be positioned so that wiring is taken into the wireways within a
short distance of the terminals on the device. If a loom is necessary, suitable metal standoffs
will be required for fixing and forming of the loom. Stand-offs shall either be screwed or epoxy
glued to the board double sided "mirror" tape will not be acceptable.

PB.8.15

The wiring shall not preclude the removal or block the access to any component. The wiring
must be arranged and the devices spaced so that the labels which are fixed to the mounting
plate are not obscured by the wiring.

PB.8.16

All cables and wiring is to be identified by numbered ferrules at every termination according to
the schematic diagram and tables. Wrap around or "stick on" ferrules are not acceptable.

PB.8.17

Neutrals shall be numbered so as to clearly and easily identify each neutral with its
corresponding phase conductor.

PB.8.18

Cable colours for wiring purposes shall be as indicated in the following. Colour coding shall be
discussed with the Employer, when foreign equipment, wired to different standards, is to be
incorporated in the installation :

PB.8.19

23065

(a)

Single phase distribution boards shall be wired in red and black PVC
insulated conductors.

(b)

Three phase distribution boards shall be wired in red, white and blue PVC
insulated conductors.

(c)

General control wiring shall be orange and be taken from the blue phase.
Phase sensitive control wiring is to be wired in the phase colour.

(d)

Unearthed and DC control wiring shall be grey for negative and purple for
positive.

(e)

Neutral connections shall be black and this colour must not be used for any
other connection.

(f)

Earth connections only shall be striped green-yellow PVC insulated

conductors.

A terminal strip of the "Klippon" or similar type, if required for external connections, shall be
conveniently and horizontally positioned and located no less than 100 mm above the gland
plate. The terminal mounting rails shall be made longer than required to allow a 20 %
future expansion. Wiring connected to such a terminal must be fitted with pin ferrules. Bare
conductors are not to be directly inserted into the terminal connectors.
SS36

PB.8.20

All DC and instrument terminals shall be separated from other terminals.

PB.8.21

Plastic "chocolate block" terminals with pinch screws will not be acceptable.

PB.9

TYPICAL ARRANGEMENT DRAWINGS

PB.9.1

The following typical arrangement drawings are included as a guide and illustrate the desired
arrangement concepts.
In pricing and engineering the boards, cognisance must be taken of the actual constraints
imposed due to the location of the board within the building, manner of installation, number
and size of the circuits, cable entries and access and routing limitations within the building.

PB.9.1.1 STDE/D007 :

3-phase distribution board with sub-distribution.

PB.9.1.2 STDE/D008 :

3-phase distribution board without sub-distribution.

PB.9.2

23065

Notwithstanding anything to the contrary, where the successful tenderer has tendered
on main and sub-distribution boards manufactured by non-recommended suppliers,
acceptance of the tender shall be subject to the non-recommended supplier providing
equipment, material, workmanship and standards equal to or better than the
recommended suppliers and to the approval of the Employer.

SS37

M AI N DB
DESI G N
TI O N LABEL
A

SECTI O N LABEL
S

M AI N S
WI T
H
C
LABEL

FRONT E LE VATION W ITH DOORS IN P LACE

2P

1P

BLANK
S

SI NG LE PHASE

SUB-

SECTI O N
DI S
TRI BUTI O N
SECTI O N

SECTI O N
I SO LA
OR
T
N
LAR
G E FRAM E
I SO LA
OR
T

FUSES, TI M E S
WI T
H
C
AND C
O NTR
O L G EAR

M AI N S
WI T
H
C

SIDE EL EVAT ION

FRONT EL EVAT ION

W IT H DOORS REM OVED

DRA
WN :

SC
ALE :

TE :
A
D

23065

M DC/ PP

N. T
. S.

5/ 5/ 94

T YPICAL SURFACE WAL L M OUNT ED

3 PHASE DISTRIBUT ION BOARD
W IT H SUB-DIST RIBUT ION

SS38

DRA
W I NG No :

STDE /D007
REV :

DESI G N
TI O N
A
LABEL

M AI N S
WI T
H
C
LABEL

OUTE R V IE W W ITH DOOR CLOS E D

1P

2P

BLANK
S

3P

LAR
G E FRAM E
I SO LA
OR
T

3P

M AI N
WI T
S
H
C

FRON T E LE VATION

S ID E E LE VATION

W ITH DOOR RE MOV E D

DRA
WN :

SC
ALE :

TE :
A
D

23065

M DC/ PP

TY P ICA L FLUS H WA LL MOUNTE D

N. T
. S.

3 P H A S E DISTR IB UTION BOA R D

5/ 5/ 94

W ITHOUT S UB -DISTR IB UTION

SS39

DRA
W I NG No :

STDE /D008
REV :

PB.10

MARKING AND LABELLING

PB.10.1

The requirements of SANS 10142 must be complied with.

PB.10.2

The assemblies shall be fitted with identification labels engraved with the reference logos
indicated on the wiring diagrams. The labels shall be affixed to the front of the panels or in
a similar prominent position, by drive screws or other approved method.

PB.10.3

All components shall be identified as per their designation on the schematic diagrams by
engraved plastic laminated labels mounted above the component. The letters should be at
least 8 mm high, black on white background.

PB.10.4

All busbar chambers to be clearly marked with the following information: service voltage,
current carrying capacity and fault level and duration.

PB.10.5

Each individual item of equipment installed in the panels shall be identified by a label
engraved with the corresponding diagram reference. The label is to be secured
immediately below or close to the device it is identifying, but not on the device itself. The
label must not be covered by the wiring. Self-adhesive tape labels will not be considered
suitable for this purpose.

PB.10.6

Each wiring termination of a motor control panel and all control wiring in other assemblies
shall be fitted with a solid concentric cable marker engraved with the corresponding
diagram reference number. Clip-on and stick-on cable markers will not be considered
suitable for this purpose.

PB.10.7

Where an outgoing terminal block is provided, each individual terminal shall be marked with
the corresponding diagram reference number.

PB.10.8

Purpose-made labels shall describe the various sections or functions of the panels, to
facilitate the identification of the equipment and relate it to the diagrams.

PB.10.9

The usual warning labels, marker's label and rating plate shall be affixed in suitable
positions. A copy of the wiring diagram and spare parts list shall be stored in a plastic
envelope within the enclosure, unless otherwise directed by the Employer.

PB.10.10

Legend card holders are to be made of metal with a clear PVC front and welded to the front
of the board (without doors) in a suitable position or to the inside of a door.

PB.10.11

The description on the legend card must clearly indicate the location of the circuit as well as
the circuit type, e.g. "Plugs : North Classroom".

PB.10.12

All switchboards and distribution boards shall be fitted with a standard bilingual label
"IN CASE OF ACCIDENTAL CONTACT ISOLATE MAIN SWITCH"
mounted directly below the main isolating switch and the size of the cable supply.

PB.10.13

23065

All sub-distribution boards shall have a label fixed below the main switch which shall
indicate the source of the main feeder cable supply and the size/cores of the cable.

SS40

PB.11

SWITCHGEAR & PROTECTIVE DEVICES

PB.11.1 Air Circuit Breakers (ACB's)

PB.11.1.1

Air circuit breakers must comply with IEC 60947-2. The rated service short circuit breaking
capacity (Ics) shall be equal to, or greater than, the specified required fault level of the
switchboard in which it is to be used.

PB.11.1.2

ACB's shall be of utilisation category "A" and have a short circuit withstand capacity of one
second.

PB.11.1.3

Withdrawable ACB's must be provided with an interlock on the cradle which prevents a
closed ACB from being withdrawn from, or inserted into, the power circuit. The cradle must
clearly indicate "Service", "Racked Out" and "Test" positions.

PB.11.1.4

ACB's must be provided with at least the following overloads :

(a)

An adjustable thermal overload with at least a range of 0,5 to 1,0 of the

rated current.

(b)

A short circuit overcurrent delay, adjustable both in time in at least steps

of 0, 0,1, 0,2 and 0,3 seconds and in current up to 10 times the rated
full load current of the ACB.

PB.11.2 Moulded Case Circuit Breakers (MCCB's)

PB.11.2.1

A MCCB is defined in this specification as a large frame circuit breaker with at least 3 poles
and with a breaking capacity of greater than 10 kA at 400 V.

PB.11.2.2

MCCB's must at least comply with SABS 156. In addition, for breaking capacities of 30 kA
at 400 V, or higher, the devices must also comply with IEC 60947-2. The rated service short
circuit breaking capacity (Ics) shall be at least equal to 50% of the specified required fault
level of the assembly in which it is to be used.

PB.11.3 Miniature circuit breaker (mcb)

PB.11.3.1

Mcb's are defined, in terms of this specification, as small frame circuit breakers of 1, 2, 3 or
4-pole type with breaking capacities up to 10 kA at 400 V or up to 50 kA at 400 V for current
limiting types.

PB.11.3.2

Mcb's shall at least comply with SABS 156.

PB.11.4 Earth leakage circuit breakers (ELCB's)

PB.11.4.1

The earth leakage personnel protective relays and circuit breakers shall operate on the
core balance principle and energize the trip coil by means of a static switching device of
simple design.

PB.11.4.2

The sensitivity and response of the relay shall cause the instantaneous tripping of the
isolator when the earth leakage current reaches 30 mA.
The relay is to be fitted with integral test facilities and shall be compensated for ambient
temperature variations and severe earth fault currents.

PB.11.4.3
PB.11.4.4

23065

Earth leakage relays protecting installations against earth leakage damage shall be of
similar design and cause the isolator to trip when the total earth leakage current reaches
250 mA.
SS41

PB.11.4.5

Earth leakage relays supplying 3-phase, 4-wire supplies, shall be of the 4-pole type.

PB.11.4.6

Earth leakage relays shall comply in all respects with SABS 767.

PB.11.4.7

An earth leakage relay shall be fitted to all circuits that feed socket outlets, except those for
special applications, and all circuits that supply water pumping equipment.

PB.11.5 Combination Fuse Switches (CFS's)

PB.11.5.1

Combination fuse switch units shall be triple pole devices fitted with neutral links and shall
comply fully with SABS 152 or BS EN 60947.

PB.11.5.2

The fuse switches shall be of the on-load type capable of carrying the rated current
continuously, making and breaking rated current and tested to IEC 60947 for making and
breaking capacity.

PB.11.5.3

The units shall be of the double air-break, quick-make, quick-break type with an arc
chamber. The mechanism shall be driven by springs on both sides.

PB.11.5.4

The unit shall consist of a fixed contact assembly, heavy duty mechanism, moving contact
carriage and a retractable operating handle mounted on a rigid frame. The contacts shall
be of high quality material, e.g. silver plated.

PB.11.5.5

The fixed contacts shall be shrouded.

PB.11.5.6

When the fuse switch is in the open position, the double air break shall fully isolate the
HRC fuse links, permitting fuse replacement in safety.

PB.11.5.7

Interlocks shall be provided to prevent the cover from being opened when the switch is
"ON" and to prevent the switch from being operated when the cover is open, unless
purposely defeated.

PB.11.5.8

The cartridge fuses used in the units shall comply with SABS 172 or BS 88 or the
equivalent DIN and VDE Standards. The category of the duty shall be suitable for the
voltage level and the fault level at the point where the fuses are installed. Time/current
characteristics shall be matched to the equipment supplied and protected by the switch.

PB.11.5.9

Fuse gear carrying the HRC fuses on the cover, the cover also forming the operating lever,
is regarded as a fuse isolator and is not acceptable.

PB.11.6 Cartridge Fuses and Fuse Holders

This section covers cartridge fuses and holders used for the protection of distribution and
power system equipment up to 600 V :
PB.11.6.1

Types
The following fuse and fuse holder types are acceptable for use in distribution and power
systems :

23065

(a)

A cartridge type fuse link which fits into a fuse carrier together with a fuse base with
fixed terminals. The fuse can be removed by taking out the fuse carrier and then
removing the fuse from the carrier.

(b)

A cartridge type fuse link which fits into a fuse base with fixed terminals. In this
case a fuse puller is required to disengage the fuse from the base. These fuses are
only acceptable on equipment imported with these fuses as a standard item. One
puller shall be supplied for each board or box in which these fuses are used. The
fuse puller shall be mounted in a spring clamp inside the board.

SS42

Rewirable fuses are not acceptable and shall not be used.

Fuses shall normally be installed in moulded plastic fuse holders or rigid isolating
barriers shall be installed between the fuses. Sufficient spacing to prevent
accidental contact when inserting or withdrawing fuses shall be maintained. The
covers or barriers shall be manufactured for the specific fuses to be used.
Striker pin fuses shall be equipped with an alarm contact so that the contact closes
and remains closed when the striker pin operates.
PB.11.6.2

Standards
All fuses used for distribution systems shall comply with the following standards :

PB.11.6.3

(a)

Fuses

SABS 172 or BS 88, Parts 1 and 2.

(b)

Holders

SABS 173.

(c)

Fuses of the types described in para PB.11.6.1 above and complying with the
relevant DIN (49510, 49511, 49515, 49522, 49360, 49367) and VDE (0635,
0660) Standards are also acceptable.

Ratings

(a) Fuse ratings shall be accurate to within +5% of the published value for unused fuses
and shall not vary significantly after long periods of service.
(b)

Fuses shall be derated for ambient temperatures above 25C in accordance with the
manufacturer's recommendation. If no such recommendation exists, a derating factor of
1% per C above 25C shall be applied.

(c)

Fuses shall be derated for elevations of more than 1000 m above sea level in
accordance with the manufacturer's recommendation. If no such recommendation
exists, a derating factor of 1% per 300 m above 1000 m above sea level shall be
applied.

(d)

Time/current characteristics shall be chosen to suit the application :

(e)

23065

Cable Protection

: The fusing shall not exceed 1,5.

Motor Circuits

: Time lag characteristic so that the starting currents

will not cause deterioration of the fuse.

Capacitor Circuits

: Fuses shall be chosen to withstand a higher than

normal full-load current (1,5 times rated capacitor
current) to allow for harmonics and shall not
deteriorate due to the high transients at switch-on.

Distribution Systems

: The total operating I2t let through by secondary

(minor) fuses shall be less than that of primary
(major) fuses in any specific branch.

It shall be ensured that the rupturing capacity of a fuse chosen for a specific application
shall be adequate, both as far as short circuit current and applied voltage are
concerned.

SS43

PB.11.7 Triple Pole On-Load Switches

PB.11.7.1

This section covers switches suitable for panel mounting for use in power distribution
systems up to 600 V, 50 Hz. Switches for motor isolation are included.

PB.11.7.2

The switches shall be of the triple-pole, hand operated type, complying with SABS 152.

PB.11.7.3

The switches shall have a high speed closing and opening feature.

PB.11.7.4

The switches shall be suitably rated for the continuous carrying, making and breaking of the
rated current specified. The through-fault current capacity must be at least equal to the
specified prospective fault level for one second.

PB.11.7.5

To distinguish the switches from circuit breakers the operating handles shall have a
distinctive colour and/or the switch shall be clearly and indelibly labelled "ISOLATOR".

PB.11.8 Contactors
PB.11.8.1

Contactors shall be of the totally enclosed, four, three or two pole, electro-mechanically
operated air break type, suitable for 400 V / 230 V supplies and comply with SABS-IEC
60947/4.

PB.11.8.2

Contactors shall be of modern design with the following characteristics :

(a)
(b)
(c)
(d)

Enclosed coil easily replaceable.

A permanent air gap in the magnetic circuit to prevent sticky operation.
Provision for quick and simple inspection of contacts.
Clearly marked main and auxiliary terminals.

All parts shall be accessible from the front.

PB.11.8.3

Contactors which are not located in switchboards shall be housed in enclosures which
comply with IP.54 of SABS 1222.

PB.11.8.4

The current rating of the contactor shall be as specified for the circuit with a switching duty
in accordance with the following utilisation categories of SABS-IEC 60947/4 :
(a)

AC 1 :

Resistive heating.

(b)

AC 3 :
:

Starting indication motors;

Switching fluorescent and incandescent lighting circuits.

(c)

AC 6(b)

Capacitor switching.

PB.11.8.5

In MCC's or switchboards where the prospective fault level is 20 kA or higher, contactors

must be selected to give Class 2 co-ordination to SABS-IEC 60947/4.

PB.11.8.6

The magnetic system of the contactor shall be carefully designed and all laminations tightly
clamped to ensure that when the armature is closed and full voltage at normal frequency is
applied to the coil, the contactor will not emit more noise than the hum associated with any
properly constructed laminated core with tightly clamped laminations. Noisy contactors will
not be accepted.

PB.11.8.7

Latched contactors shall be provided with a trip coil and a closing coil. The contactor shall
remain closed after de-energising the closing coil and shall only trip on energising the trip
coil.

PB.11.8.8

Contactor operating coils shall have a voltage rating as required by the control circuitry and
shall have the limits of operation and temperature rise as specified by SABS-IEC 60947/4.

23065

SS44

Latched contactors shall be capable of being tripped at 50% of the rated coil voltage. Coils
operating on 230 volts would be preferred.
PB.11.8.9

Contactors for normal/standby changeover circuits shall be electrically and mechanically

interlocked. Contactors shall also be electrically interlocked in star-delta starters.

PB.11.8.10 Contactors shall have the provision to add auxiliary contacts and convert auxiliary contacts
on site. Contactors with permanently fixed auxiliary contacts shall have at least 1 x N/O
and 1 x N/C spare auxiliary contact in addition to the contacts specified for control purposes
and in addition to contacts required for self-holding operations or economy resistances.
Where the number of auxiliary contacts required is greater than the contacts that can be
accommodated on the contactor, an auxiliary relay or additional contactor shall be provided
to supply the additional contacts.
PB.11.8.11 It shall be possible to replace main contacts without disconnecting wiring.
PB.11.8.12 Auxiliary contacts shall be capable of making, carrying continuously and breaking 6 A at
230 V AC, unity power factor for contactors used on 400 / 230 V systems.
PB.11.8.13 Auxiliary contact functions required, e.g.
"lazy" contacts, late-make, late-break,
make-before-break, etc., shall be inherent in the contact design. Under no circumstances
may these functions be improvised by bending contacts, loading contacts, etc. These
functions shall be available in all contactors.
PB.11.8.14 Spare auxiliary contacts shall be wired to numbered terminal strips in the switchboard and
shall appear on the switchboard drawings.
PB.11.9 Overload Relays for Contactors
PB.11.9.1

All overload relays are to comply with SABS-IEC 60947/4-1 and must provide protection
against both overload and single phasing conditions.

PB.11.9.2

Thermal overload relays must be temperature compensated and provide galvanically

isolated auxiliary contacts for tripping and indication. Both manual and auto-reset facilities
must be provided.

PB.11.9.3

Electronic overload relays must be used for motors of 55 kW and larger, unless otherwise
specified. The relay must have the facility to set the starting time of the drive and must trip
instantaneously in the case of single phasing.

PB.11.10

Electronic Motor Protection Relays

PB.11.10.1

Electronic motor protection relays must comply with SABS-IEC 947/4 as applicable and
be suitable for use on 400/230 V systems.

PB.11.10.2

The relay must be provided with a sealable cover, behind which the settings of the unit
are made. A reset button must be accessible without removing the cover.

PB.11.10.3

The relay must provide indication by means of LED's, of the cause of the trip out and
also indicate the operational readiness of the unit.

PB.11.10.4

At least the following protection facilities must be provided :

23065

PB.11.10.4.1

Thermal overload

PB.11.10.4.2

Anti-Single phasing

PB.11.10.4.3

Stall protection
SS45

PB.11.10.4.4

Phase sequence protection

PB.12 INDICATING INSTRUMENTS

PB.12.1.1

All electrical equipment for a particular application shall be supplied from the same
manufacturer, shall be splashproof and dustproof and have the same face dimensions.
The face dimensions shall be square and not less than 96 x 96 mm. Anti-static impact
resistance glass shall be used on the face.

PB.12.1.2

All instruments shall conform to BS.89 and/or IEC.6051.

PB.12.1.3

Instruments shall be rated for 2 kV insulation resistance to earth.

PB.12.1.4

Instruments shall be capable of withstanding overloads of continuous or short duration in

accordance with IEC.6051 (1,2X / 10X ).

PB.12.1.5

Instruments shall be provided with either recessed or shrouded studs for rear connection.
All rear connections shall conform to at least IP 20.

PB.12.1.6

Instruments shall be sufficiently resistant to vibration that may be encountered.

PB.12.2 Kilowatt-Hour meters

PB.12.2.1

Unless specified to the contrary, kilowatt-hour meters shall be suitable for operation on
220/250 V, 50 Hz, systems.

PB.12.2.2

Meter elements shall be of the inductor disc type and designed to carry the rated current
continuously.

PB.12.2.3

Kilowatt-hour meters shall comply with the relevant parts of BS 5685-3. The integrating
period on maximum demand meters shall be 30 minutes unless specified to the contrary.

PB.12.2.4

The registering mechanism shall be of the cyclometer type, providing a six digit read-out
with the sixth digit indicating one tenth of a unit.

PB.12.2.5

Unless specified to the contrary, the meters shall conform to accuracy Class 1, as specified
in IEC.6051.

PB.12.2.6

Kilowatt-hour meters shall be graded and calibrated for the specific application to avoid the
application of multiplication factors where possible. Where multiplication factors are
unavoidable this shall be clearly indicated in unit form and not as a combination of several
factors. Current transformer ratios shall be incorporated in the factor.

PB.12.2.7

The kilowatt-hour meter shall preferably be provided with a magnetic type of bearing for the
disc spindle.

PB.12.2.8

Facilities for a security seal shall be provided on the fixing screws of the cover.

PB.12.2.9

kWh meters with pulsed output are to be single or 3-phase units as applicable. A 6-digit
cyclometer display is to be provided and the one-tenth digit may be omitted. A maximum
error of 2% is to be provided. The pulse output, which is to be provided by voltage free
contacts, must correspond to 1 kWh/pulse.

PB.12.3 Voltmeters and selector switches

PB.12.3.1

23065

For LV applications, all voltmeters shall be scaled from 0 - 500 volts, unless otherwise
specified.

SS46

PB.12.3.2

Voltmeters shall be of the moving iron type, Class 1.5 accuracy as specified in IEC.6051.
Zero adjustment screws shall be provided.

PB.12.3.3

Unless otherwise specified, a single voltmeter shall be used with a selector switch. The
voltage selector switch shall have an "OFF" position and positions for indicating readings
between each phase and neutral and between phase and phase.

PB.12.3.4

The voltage selector switch shall be cam actuated or of the air break type with two breaks
per pole.

PB.12.4 Ammeters
PB.12.4.1

Ammeters shall have a moving iron element to indicate instantaneous values as well as a
zero adjustment screw for the indicating arm.

PB.12.4.2

Ammeters may be direct reading up to a maximum of 60 amps. Current transformer

operated ammeters shall have the CT ratio indicated on the face plate and shall be rated
for 5 amps full scale reading actual primary circuit currents.

PB.12.4.3

Where combined maximum demand and indicating ammeters are detailed, a bi-metallic
spiral element shall be provided in the same housing to indicate mean value over a 15
minute period.

PB.12.4.4

The bi-metal element shall drive a residual pointer to indicate maximum mean current
between resettings. This pointer shall operate on the main scale and shall be of a
distinctive colour. The pointer shall be resettable from the face of the meter.

PB.12.4.5

The bi-metal element shall be designed to compensate for limits of ambient temperature
between (-)20C and 70C.

PB.12.4.6

Full load or rated current shall be clearly indicated, preferably with a red line. Unless
specified to the contrary, a 100% condensed overscale shall be provided for instantaneous
reading instruments and no overscale for combined maximum demand ammeters.

PB.12.4.7

The intrinsic error, expressed in terms of the fiducial value in accordance with IEC.6051
shall be Class 1.5 for the instantaneous readings and Class 2.5 for the mean maxima.

PB.12.4.8

Where saturation current transformers are required, these shall be an integral part of the
meter. Separate saturation current transformers will not be permitted.

PB.12.5 Frequency meters

PB.12.5.1

Frequency meters may be of the vibrating reed type or the direct indicating type consisting
of a moving coil milli-ammeter and a current/frequency transducer.

PB.12.5.2

Unless specified to the contrary, the indicating range shall be 45 Hz - 55 Hz.

PB.12.5.3

The accuracy class shall be Class 0,5 in accordance with IEC 6051 unless otherwise
specified.

PB.12.5.4

Where required, an adjustable speed alarm contact shall be provided, adjustable over the
complete scale length.

PB.12.6 Running hour meters

PB.12.6.1

Running hour meters shall be of the electrically operated cyclometer type, suitable for flush
mounting.

PB.12.6.2

Numerals shall be clearly defined White on a Black background.

23065

SS47

PB.12.6.3

The range of hour meters shall be five digits, the fifth digit indicating one-tenth of an hour,
i.e, from 0 to 9999,9 hours.

PB.12.6.4

The accuracy class shall be Class 1 in accordance with IEC.6051 unless otherwise
specified.

PB.12.7 Current transformers

PB.12.7.1

General
Current transformers shall comply with the requirements of SABS IEC 6044-1.

PB.12.7.2

Ratings
(a)

Current transformers shall be suitable for the primary currents listed hereunder
and their decimal multiples :
10, 12.5, 15, 20, 25, 30, 40, 50, 60 and 75
The preferred values are :
10, 15, 20, 30, 50 and 75

PB.12.7.3

(b)

Current transformers shall have secondary ratings of 1 A or 5 A, with 5 A being

preferred.

(c)

Current transformers shall have standard outputs of 2.5, 5, 10, 15 or 30 VA

as applicable, in terms of the burden of the instruments and inter-connecting
wiring. The current transformer output shall match the actual instrument burden
as closely as possible in order not to introduce unnecessary errors.

Accuracy class
(a)

For metering applications, accuracy classes 0.5 or 1 are applicable. Where no

accuracy class has been specified, the following table is to be adhered to:
Application

PB.12.7.4

Class

Indicating instruments

Metering applications

Precision metering applications

and bulk metering

0,5

(b)

Where ring type current transformers are specified, the aperture shall not be
unnecessarily large as accuracy is thereby reduced.

(c)

The classes for protection are 5P, 10P, 15P, 20P or 30P with 5P and 10P
being standard. Turns compensation shall not be employed on protection
current transformers for ratios greater than 150/5.

All current transformers shall come complete with a label on which the following information
is indelibly stamped :
Manufacturer
Serial Number or Type
Rated primary and secondary current
Rated frequency
Rated output and accuracy class

23065

SS48

Highest system voltage

Rated insulation level
PB.12.7.5

Current transformers shall be capable of withstanding the dynamic forces and thermal
stress resulting from the maximum through-fault current which may be encountered at the
point where they are installed. The short time current rating of current transformers shall
correspond to the maximum short circuit current at the point of connection flowing for a
period of 1 second.

PB.12.7.6

Impulse levels for current transformers used in system voltages up to 660 V shall comply
with SABS IEC 60044.

PB.13

MISCELLANEOUS CONTROL EQUIPMENT

PB.13.1 Indicator lights

PB.13.1.1

Indicator lights may only be of the neon or LED types. Lamp voltages shall suit the supply
or control voltage. Lamps shall be de-rated for continuous duty by using economy resistors
or using input voltages at least 20% lower than the rated lamp voltages.

PB.13.1.2

Where LED's are used as indicators on main supply voltages a suitable current limiting
capacitor and reverse voltage protection diode must be used. For low AC or DC voltages
( 24 V ) a current limiting resistor will suffice.

PB.13.1.3

Indicator lights shall conform to BS.1050 where applicable.

PB.13.1.4

Indicator lamps shall consist of inter-changeable lenses, lamp base, suitably rated and
accessible terminals and a chromed screw-on retaining ring. All indicator lights for a
specific application or switchboard shall be from the range of one manufacturer and shall
preferably be of the same size and shall use the same lamp types. Plastic lenses shall not
be used.

PB.13.1.5

It shall be possible to replace lamps from the front of the panel without the use of tools.

PB.13.1.6

Surface mounted indicator lights shall be housed in purpose-made boxes with suitable
cover plates.

PB.13.1.7

Indicator lights shall be equipped with standard removable legend plates. Alternatively, the
function shall be clearly indicated by means of labels or by engraving on the lenses.
All indicator lights for a specific application or switchboard shall be from the range of one
manufacturer and shall preferably be of the same size and shall use the same lamp types.

PB.13.1.8
PB.13.1.9

The following are the preferred colours for indicator lights :

(a)RED

Abnormal State or Motor Off

(b)YELLOW (or Amber) :

Attention, or Caution, or Motor Tripped

(c) GREEN

Motor Running

(d)WHITE (or Clear)

Circuit Live or Circuit Operating Normally

(e)BLUE

Any function not covered by the above colours.

PB.13.2 Panel mounted push buttons

PB.13.2.1

23065

All push buttons on a specific switchboard shall be of the same physical dimension (round
or square) and shall be fully inter-changeable as far as possible. Push buttons must
preferably be inter-changeable with indicator lamps, key switches, etc.
SS49

PB.13.2.2

Push buttons shall be designed for long life, low contact bounce and constant contact
resistance. Mechanisms may be of the mechanical type with spring control and a clutch or
catch frame or of the solid state type operating on the principle of a non-contacting,
inductive proximity switch.

PB.13.2.3

All push buttons shall be provided with replaceable lenses with a variety of symbols for
insertion and for removable and inter- changeable legend plates. Legend plates shall be
clear and versatile.

PB.13.2.4

Push button terminals shall be suitable for the application with regard to spacing, conductor
capacity, etc.

PB.13.2.5

Screw type, soldered or connector type terminals shall be chosen to suit the specific
application with regard to good contact, ease of removal or alteration, rigidity, etc. Terminals
shall be suitable for conductor sizes to be used. Push button assemblies mounted on
doors of control boards shall be enclosed to prevent inadvertent contact with the terminals.

PB.13.2.6

Push buttons shall be suitable for the environmental conditions to be encountered, e.g.
moisture, excessive temperatures, mechanical shock, vibration, etc.

PB.13.2.7

Contact duty shall be chosen to suit the application. Wiping contacts shall be used for low
voltages and currents and snap-action contacts for high voltages and currents. Contacts
shall be constructed of high quality material such as silver-tipped or gold laminated
contacts.

PB.13.2.8

Illuminated push buttons may employ neon or LED lamps. Lamp voltages shall suit system
control voltages. Lamps shall be derated when used for continuous duty, e.g. using 20 V
supply on 28 V rated lamps. External resistors shall be used with LED lamps to avoid
excessive current.

PB.13.2.9

Push buttons may be grouped together in purpose-made stations, suitable for the
environment in which it is to be installed.

PB.13.2.10 Keylock push buttons shall be supplied with duplicate keys. The removal action of the key
shall suit the application.
PB.13.2.11 Push buttons shall comply with the applicable requirements of BS.3955 Part 3 and
IEC.60947.
PB.13.3 Rotary CAM switches
PB.13.3.1

This section covers rotary cam switches used for control functions in switchboards, motor
control circuits, etc., up to 1 kV AC.

PB.13.3.2

The switches shall be equivalent to KLOCKNER-MOELLER Type T rotary cam switches

and shall conform to IEC.60947-5-1 and VDE.0113, where applicable.

PB.13.3.3

The switches shall be of the cam actuated type with two breaks per pole, the required
number of poles and number of control functions provided by the assembly of switching
units on a common spindle.

PB.13.3.4

The spindle shall be operated by a control handle suitable for the method of installation of
the switch. The control handle shall be located by a keyway on the spindle.

PB.13.3.5

The switches shall be provided with a suitable face place, indicating the angle of throw and
the switch positions. The latching mechanism shall ensure positive positioning in accurate
relation to the positions indicated on the face plate.

23065

SS50

PB.13.3.6

The switches shall be suitable for use with the supply voltage level. The contacts shall be
silver plated or gold laminated and shall be suitably rated for the switching functions
intended.

PB.13.3.7

For normal applications the making capacity of the switch shall be at least three times the
normal current rating. For AC.4 duties (inching, reversing, plugging), the rated current of
the switch shall be at least equal to the stalled rotor current of the motor.

PB.13.3.8

Special contacts, e.g. late-making, early-breaking, etc., shall be inherent in the design and
shall not be improvised by loading or bending contacts, etc.

PB.13.4 Motorised Time Switches

PB.13.4.1

Time switches shall be of the single pole type, suitable for 230 V systems, with contacts
rated for the duty to be performed with a minimum AC1 rating of 16 A. Contacts shall be of
high quality material, e.g. silver plated or solid silver. The time switch shall be rated for
operation in the temperature range -10C to +50C

PB.13.4.2

The clock shall be driven by a crystal controlled stepping motor, keeping accurate mains
time. All clocks shall have a 72-hour rechargeable battery reserve in the event of mains
failure.

PB.13.4.3

The motor shall be separately protected by a correctly rated single pole MCB.

PB.13.4.4

A manual bypass switch shall be provided to permit the circuit to be switched "ON" or
"OFF" manually without affecting the operation of the time switch.

PB.13.4.5

Daily time-switches shall have a 24 hour dial, with day and night indication, that can be set
with a minimum accuracy of 30 minutes unless specified otherwise.

PB.13.4.6

Weekly time-switches shall have a 7-day dial, with clear indication of the days of the week
that can be set to a minimum accuracy of 4 hours.

PB.13.4.7

Switches intended for incorporation into distribution boards must be suitable for rail
mounting.

PB.13.4.8

The switch intended for wall mounting shall be housed in a dust-tight moulded plastic or
metal case, consisting of a plastic clip-on front cover and a moulded plastic or metal base
and be provided with a suitable positioned 20 mm conduit knock-out.

PB.13.4.9

When required, motorised time-switches are indicated as either "T" or "MT" on the
schematics or schedules.

PB.13.5 Digital Time Switches

PB.13.5.1

Digital time switches shall be of the single channel type, suitable for 230 V systems with
contacts rated at least 16 A, 230 V, AC1.

PB.13.5.2

The switch shall be micro-processor based with at least a 100 hour battery reserve. The
operating temperature range shall be at least 10C to +45C.

PB.13.5.3

The switch is to be provided with a liquid crystal display for indicating time and/or the
settings. The time stability shall be at least 1 second/day. The display must also indicate
the operating condition (ON/OFF) of the switch.

PB.13.5.4

Daily time switches shall have a setting capacity of 12 programme steps (6 programme
pairs).

PB.13.5.5

Weekly time switches shall have a setting capacity of at least 128 switching times.

23065

SS51

PB.13.5.6

The minimum switching time is to be not more than 1 minute.

PB.13.5.7

Switches are to be provided with a clip for DIN rail mounting and must be enclosed in an
IP 52 box, if wall mounted.

PB.13.6 Programmable Electronic Timers

PB.13.6.1

Timers must be of the plug-in module construction. Each timer is to be housed in a dust
tight housing with the timing range clearly marked on the front and must be provided with a
calibrated setting knob.

PB.13.6.2

The timer must be suitable for either 230 or 400 V operation, as applicable, and have a
contact rating of 10 A/230 V AC1 for single pole or 5 A/230 V AC1 for double pole. Contact
life is to be at least 100 000 operations at full load.

PB.13.6.3

The operating temperature range is to be at least 10C to +50C.

PB.13.6.4

The time adjustment range must be at least 12:1.

PB.13.6.5

The front of the timer must be provided with a small indicating light to show the relay is
energised.

PB.13.7 Micro-gap switches

PB.13.7.1

Microgap switches shall be suitable for ratings up to 400 A at 660 V (triple pole) and may
be used for main and distribution switches in domestic applications, offices, small factories
and similar applications.

PB.13.7.2

Double pole switches shall be suitable for voltages up to 250 V.

PB.13.7.3

The switches shall comply with SABS 152.

PB.13.7.4

Microgap switches may be used on AC circuits only.

PB.13.7.5

Metal clad and moulded casings are acceptable.

PB.13.7.6

Microgap switches shall be capable of carrying rated current continuously and making and
breaking rated current.

PB.13.7.7

Heavy, fully accessible, brass terminals with two screws each shall be provided to facilitate
easy wiring. Contacts shall have large contact surfaces, made from high quality material
such as solid silver.

PB.13.7.8

The "ON" and "OFF" positions and the rating of the switch shall be clearly and indelibly
marked.

PB.13.8 Indoor Surge Arrestors

PB.13.8.1

Surge arrestors shall be of the gapless metal oxide type and shall comply with the
requirements of SABS-IEC 6099-4 or SABS-IEC 61643-1 or VDE 0675.
Low voltage surge protection devices shall be fitted to each phase and neutral of all main
distribution boards and motor control boards, irrespective of the lightning ground flash
density of the area.

PB.13.8.2

Arrestors intended for use on 230 V systems must have a rated voltage of not less than
270 V.

PB.13.8.3

Arrestors shall at least have a rated nominal discharge current of 5 kA. The residual voltage
at a 5 kA discharge current shall be less than 1 kV.

23065

SS52

PB.13.8.4

Surge arrestors shall be suitable for installation at altitudes of up to 1800 m above sea
level.

PB.13.8.5

The unit shall be supplied complete with a galvanised steel mounting bracket for
convenient mounting onto the metalwork or tray of a switchboard.

PB.13.8.6

Alternatively, the unit shall be of the type which can be mounted into the clip tray of a
switchboard or for DIN rail mounting.

PB.13.8.7

Surge arrestors shall be provided in all cases where a switchboard is supplied directly from
an overhead line.

PB.13.8.8

In other cases, surge arrestors, if required, will be specified in the "Detailed Technical
Specification".

PB.13.9 Terminal Connectors

PB.13.9.1

Terminal connectors shall hold the conductor by means of a clamping plate held down by
the securing screw.

PB.13.9.2

Connectors shall be of the individual variety which are assembled on to a mounting rail and
held in place by means of a securing plate at each end.

PB.13.9.3

The minimum size used must be able to accommodate a conductor in the range 1,0 to
6 sq.mm.

PB.13.9.4

All connectors and the wires connected to them must be numbered and these numbers
reflected on the "as built" drawings.

PB.14

INSTALLATION

PB.14.1

LV switchboards and distribution boards and motor control panels shall be erected,
installed and commissioned in the positions shown on the drawings. The installation shall
be arranged to suit the general installation programme. All floor mounted switchboards
must be bolted securely to the floor.

PB.14.2

During transport to site and installation, the boards shall be protected against mechanical
damage and vibration.

PB.14.3

Boards shall not be moved onto site nor installed until all building services and finishing
trade work has been completed in the room or vicinity of where the boards are to be
installed.

PB.14.4

The boards shall be installed in such a manner as to facilitate extensions, maintenance,

testing and repair work with easy access to cable entries/ terminations, current
transformers, potential transformers, small wiring terminal boards and relays, and busbar
connections.

PB.14.5

Prior to the on-site tests, all screws, bolts, joints and cable terminations shall be checked
for tightness. Busbar joints and cable terminations must be torqued to the correct tension.

PB.15

INSTALLATION / SHOP DRAWINGS, MANUALS AND SAMPLES

PB.15.1

General

PB.15.1.1

23065

The Contractor shall provide all drawings, manuals and samples as specified below.

SS53

PB.15.1.2

Detailed drawings of all equipment shall be submitted to the Employer in triplicate for
approval well in advance of the latest ordering date and in all cases at least 2 weeks in
advance of the latest manufacturing commencement date.

PB.15.1.3

Under no circumstances will the these requirements be waived. Any delays or increased
costs due to non-compliance with these requirements will be for the contractor's account.

PB.15.1.4

The approval of the drawings shall not relieve the manufacturer of his responsibility to the
employer to supply the equipment according to the requirements of this specification.

PB.15.1.5

The Contractor is to submit two (2) copies of shop and installation drawings to the
Employer for review.

PB.15.2

Shop drawings
As a minimum, the shop drawings shall indicate schematic wiring diagrams, symbol legend,
equipment schedule and engineering construction drawings showing:

PB.15.2.1

Details of construction, front view, side view and section through board and equipment,
dust-proofing, access and cable terminations, etc.

PB.15.2.2

The internal arrangement to show details of the housing over, indicating door positions, roof
line, etc.

PB.15.2.3

A schedule cross-referenced listing all equipment within the board with the total quantities,
manufacturer's names, current ratings and time settings.

PB.15.2.4

Busbar and dropper bracing and support details including specimen calculations or test
reports in substantiation of short circuit capacity of the system.

PB.15.2.5

Busbar section and size including selection/sizing criteria and calculations in substantiation
of the full load rating.

PB.15.2.6

All labelling information in both official languages on a separate sheet.

PB.15.3

Installation drawings
As a minimum, the dimensioned installation drawings shall indicate:

PB.15.3.1

Position of switchboard relative to cable trenches, cable trays, adjacent walls and
equipment.

PB.15.3.2

Surrounding clear space between walls and adjacent equipment for access and
maintenance purposes.

PB.15.3.3

Cable entry details, and cable routing and crossover aspects when entering the board.

PB.15.3.4

Details of supports across trenches and the interface between the cable trench covers
and switchboard.

PB.15.4

Samples

PB.15.4.1

Where switchboards and sub-distribution boards are to be provided by manufacturers other

than those recommended, the contractor shall provide samples of the equipment, material,
quality and workmanship to be inspected for approval.

PB.15.4.2

These samples may take the form of existing equipment provided by the particular supplier
for previous contracts, providing the location of the equipment is local to and within 10
kilometres of the Employer's offices.

23065

SS54

PB.15.4.3
PB.15.5

The Employer may also request physical samples of items of equipment be submitted for
approval during the detailed engineering phase.
"As Built" Drawings and Manuals

PB.15.5.1

The "As Built" Drawings and Manuals shall comprise the relevant final as approved and
installed installation and shop drawings. The maintenance and fault finding manuals shall
be explicit, shall cross-reference to the drawings, schematics and control logic diagrams
and shall provide full maintenance details, requirements, methods and schedules for each
and every type of device employed. Furthermore, the manual shall contain spare parts lists
and numbers for all equipment and the names of the suppliers from whom the equipment is
to be obtained.

PB.15.5.2

Manuals must also include all test results and the settings of all protective, control and
indicating devices as applicable.

PB.15.5.3

Manuals must be provided in a hard cover loose-leaf file, properly indexed with full page
separators between each section.

PB.15.5.4

Full and detailed Technical literature and operating procedures must be provided for all
items of equipment. At least one original manual must be provided for each corresponding
item of equipment, up to the required number of three (3).

PB.15.5.5

Three (3) copies of the "As Built" drawings and Manuals shall be submitted to the Employer
within two weeks after delivery of the equipment.

PB.16

INSPECTIONS, TYPE TESTS, TESTS AND COMMISSIONING

PB.16.1

At the time of tender the manufacturer is to demonstrate compliance with item 7.5.1 of SABS
IEC 60439 part 1, that assemblies shall be so constructed as to be capable of withstanding
the thermal and dynamic stresses resulting from short circuit currents up to the rated values.
This will take the form of type test results on similar arrangements or extrapolation from type
tested arrangements or agreement to conduct short circuit tests on the completed assembly.

PB.16.2

Prior to commencement of manufacture, the contractor shall provide typical samples of the
quality of work and finish to be expected from the board manufacturer.

PB.16.3

The contractor shall keep the Employer informed of the manufacturing progress and shall
arrange periodic works and site inspections and tests as required.

PB.16.4

As a minimum, the final inspections and tests shall include :

PB.16.4.1

The provisions of SABS IEC 60439 part 1

PB.16.4.2

Visual inspection of the board, busbar, joint tightness, switchgear operation, etc.

PB.16.4.3

2 kV AC / 1 min test of all control and power circuits.

PB.16.4.4

Primary injection test of all CT's for use in protection, indication and metering circuits. This
test current must be of sufficient magnitude to verify the correct ratio of the CT and the
indicating/metering device. Electronic overloads used in ACB's and MCCB's may be tested
using secondary injection from a specialised tester provided by the Manufacturer/Supplier.

PB.16.4.5

Operation and testing of all control, indication, metering and protection systems.

PB.16.4.6

Final check of all protection system settings and the co-ordination and discrimination
between associated devices.

PB.16.4.7

Energisation of the board.

23065

SS55

PB.16.4.8

Check on phase rotation, voltage drop, load balance, earth continuity and resistance.

PB.16.5

All test results must be recorded by the Contractor and included in the manuals.

23065

SS56

PB.17

RECOMMENDED MANUFACTURERS AND SUPPLIERS

The following list of manufacturers and suppliers of electrical equipment is enclosed for the
information of Tenderers. Other makes and suppliers of electrical equipment may be
considered by the Consulting Employer but the tender shall include the following equipment
and any other makes must be quoted as an alternative offer:

23065

SS57

23065

AIR CIRCUIT BREAKERS

(ACB)

Merlin Gerin Schneider Electric

SACE
C B I Mitsubishi

MOULDED CASE BREAKERS

(MCB)

C B I Mitsubishi
Merlin Gerin Schneider Electric

COMBINATION FUSE SWITCHES (CFS)

Stromberg
Siemens

HRC FUSES AND CARTRIDGES

GEC
Brush

CONTACTORS AND OVERLOAD

RELAYS

ABB Elec. Systems

Sprecher & Schuh
Telemecanique
Siemens
Stromberg
Klockner Moller

RELAYS AND TIMERS

ABB Elec. Systems

Sprecher & Schuh
Omron
Siemens
Telemecanique

TERMINAL BLOCKS

Klippon
Telemecanique
Sprecher & Schuh

PUSH BUTTONS, SELECTOR

SWITCHES, PILOT LIGHTS

ABB Elec. Systems

Omron
Telemecanique
Siemens
Sprecher & Schuh

ELECTRIC TIMERS

Orbis
Heinemann
Duotron
Omron
Rhomberg-Brsler

GLASSFIBRE SWITCHBOARDS AND

DISTRIBUTION KIOSKS

Switchboard Manufacturers
Golnix
York

SWITCHBOARDS

Siemens, Pinetown
Gamma Panels, Durban
Switchboard Manufacturers, Phoenix, Dbn
Magnol Electrical, Durban

MOTOR CONTROL BOARDS

ABB Elec. Systems, Durban

Gamma Panels, Durban
Electron Electrical Contractors, Durban

SS58

INCORPORATED

ELECTRICAL SYMBOLS FOR SINGLE LINE DIAGRAMS

DURBAN EM PANGENI L ADYSM ITH ULUNDI

DELAYED ACTION

OPERATING DE VICE

MECHANICAL INTERLOCK BETWEEN TWO DEVICES

RELAY COIL OF A SLOW OPERATING RELAY

FUS E

LATCHING DEVICE DIS ENGAGE D

SURGE ARRESTOR
DIRECT ON LINE MOTOR STARTER

LATCHING DEVICE E NGAGED

VOLTMETER
OP ERATED BY PULLING
AMME TER

STAR DELTA STARTER

OP ERATED BY PUS HING

cos

EMERGENCY SWITCH (MUS HROOM HEAD SAFETY

POWE R FACTOR METER

HEATER

FEATURE)

OP ERATED BY KEY
CURRENT TRANSFORMER 3 PHASE WITH FOUR

Hz

FRE QUENCY METER

CONDUCTORS

OP ERATED BY THERMA L ACTUATOR, FOR EXAMPLE THERMA L

RE LAY, THERMAL OVE RCURRENT PROTECTION

RECORDING WATTME TER

DE LAY WHEN OPENING & CLOSING

THERMAL SWITCH

THREE P HASE TRANSFORMER

kWh

KILO-WATT HOUR METER

TERMINAL FOR REMOTE CONNECTION

PULSE METER (ELECTRICA LLY OPERATED COUNTING DEVICE)

RE CTIFIER IN FULL WAVE (BRIDGE) CONNECTION

CLOCK
BATTERY OF P RIMARY CELLS OR ACCUMULATORS
EA RTH
SIGNA L LAMP
1 CONDUCTOR
HORN
EARTH LEA KAGE WITH THERMAL OVERLOAD

2 CONDUCTOR

BELL
E/L
3 CONDUCTOR
SIREN
PLUG & SOCKET (MALE & FE MALE)
CIRCUIT BREAKE R
PA NEL MOUNTED PUSH BUTTON

CONNECTING LINK CLOSE D

EA RTH LEAKAGE WITHOUT THERMAL DEVICE

CAPACITOR
E/L

M
3

INDUCTION MOTOR, THREE PHASE

SQUIRREL CAGE
SWITCH DISCONNECTOR (ON LOAD ISOLATING SWITCH)

FUSE SWITCH-DISCONNECTOR (ON LOAD ISOLATING

TRANSFORMER

23065

FUSE SWITCH)

SS59

E LE CTRICA L SY MBOLS FOR

INCORP ORATE D

S INGLE LINE DIAGRA MS

DURB
AN EM P
ANG ENI LAD
SM I TH UL
Y
UNDI

PO SI TI O N S
WI T
H, M AKE C
C
O NT
CT
A
LI M I T S
WI T
H, M AKE C
C
O NT
CT
A
BREAK C
O NT
CT
A

M AKE C
O NT
CT W I TH SPRI NG RETURN
A
M AKE C
O NT
CT
A

BREAK C
O NT
CT W I TH SPRI NG RETURN
A

PUSH BUTT
ON S
WI T
H
C
( NO N L
OC
KI NG )

EM ER
G ENCY KEYED

O NT
C
CT
A
OR (C
O NT
CT O PEN I N THE
A

OC
L
KED- O UT S
OP
T
UNO PENED PO SI TI O N)

O NT
C
CT
A
OR (C
O NT
CT CL
A
O SED I N

DELA
YED M AKE C
O NT
CT
A

UNO PENED PO SI TI O N)

W HEN CL
O SI NG

DELA
YED M AKE C
O NT
CT
A

BREAK C
O NT
CT O F OVERL
A
OAD

W HEN RE- O PENI NG

RELA
Y

DELA
YED BREAK C
O NT
CT
A

THERM AL OVERL
OAD RELA
Y

W HEN RE- CL
O SI NG

PO SI TI O N S
WI T
H, BREAK C
C
O NT
CT
A
LI M I T S
WI T
H, BREAK C
C
O NT
CT
A

23065

SS60

MAIN LV DISTRIBUTION SCHEDULE

ITEMS SUBJECT TO AGREEMENT BETWEEN MANUFACTURER AND USER

Sub-clause of
SABS IEC 439

DESCRIPTION

6.1.3 (NOTE)

Use of electronic equipment at

altitudes above 1000m

6.2

Special service conditions

6.2.10
6.3.1
7.1.3.2
7.1.3.4
7.2.1.1
7.4.2
7.4.3
7.4.6
7.4.6.1
7.4.6.2
7.4.6.3
7.5.2.3
7.5.4
7.6.4.3

Electrical and radiated

interferences
Conditions during transport,
storage and erection
Means of connecting for
aluminium conductors
Current carrying capacities of
terminals for neutral conductors
Degree of protection required
Choice of protective measures
against direct contact
Choice of protective measures
against indirect contact
Accessibility in service by
authorised personnel
Accessibility for inspection and
similar operations
Accessibility for maintenance
Accessibility for extension under
voltage
Values of prospective short
circuit current for high power
rotating machines
Co-ordination of short circuit
protective devices
Degree of protection after
removal of a removable or
withdrawable part

7.7

Form of separation

7.9.1

Input voltage variations for

electronic equipment supply

7.9.4(b)

Supply frequency deviation

8.2.1.3.4
8.2.1.6
8.2.3.2.3(d)
8.3.1

Temperature rise test for values

of test current higher than
3150 A
Ambient air temperatures for
temperature rise test
Value of neutral bar current for
short circuit test
Repetition of electrical operation
test on site
SS 61

SPECIFIC REQUIREMENT