ankerlig additional storage tanks
DESCRIPTION
Power StationTRANSCRIPT
Ankerlig Power Station Specification No.
Page 1 of 48
Employers Works Information
Storage Tank
Specification for Diesel Fuel Oil and Fire Water
Rev 0
December 2011
Ankerlig Power Station Specification No.
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File Reference:
Client : Ankerlig Power Station
Project Title: Additional Diesel Storage
Report Title: Additional Storage Tank Specification for Diesel Fuel Oil and Fire water
REV. NO.: 0
Volume: 1 of 1
PRODUCED: Leonard Calana
Tinus Keyser
DATE: 6 December 2011
CHECKED: Phil Khumalo
Mjongi Mdemka
Paul Loots
Pamela Mrubata
Zahir Kapier
Nkahle Sesiu
Lynn Allies
Riaan Mouton
Saleigh Williams
DATE: 6 December 2011
APPROVED: Rodney Booth
TITLE: Plant Manager
DATE: 6 December 2011
Latest Revision Summary:
COPYRIGHT © ESKOM HOLDINGS
ALL RIGHTS RESERVED, NO PART OF THIS WORK MAY BE MODIFIED OR
REPRODUCED OR COPIES IN ANY FORM OR BY ANY MEANS - GRAPHIC,
ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING, RECORDING, TAPING OR
INFORMATION AND RETRIEVAL SYSTEM, OR USED FOR ANY PURPOSE OTHER THAN
ITS DESIGNATED PURPOSE, WITHOUT THE WRITTEN PERMISSION OF ESKOM
HOLDINGS
Ankerlig Power Station Specification No.
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TABLE OF CONTENTS
Page No.
1.1. GENERAL REQUIREMENTS ................................................................................. 6
1.1.1 Scope.................................................................................................................................................. 6
1.1.1.1 The Development......................................................................................................................... 6
1.1.1.2 Permits and Licenses .................................................................................................................. 6
1.1.1.3 Scope of the Works...................................................................................................................... 6
1.1.1.4 Exclusions .................................................................................................................................... 6
1.1.2 Site Conditions Access and Contractor’s Area ............................................................................. 7
1.1.2.1 Security ........................................................................................................................................ 7
1.1.2.2 Contractors Compound/Lay-down ............................................................................................... 7
1.1.2.3 Car Parking .................................................................................................................................. 7
1.1.2.4 Roads ........................................................................................................................................... 7
1.1.2.5 Co-operation with Other Site Service Providers/Good Neighbours Policy .................................. 7
1.1.2.6 Site Cleanliness ........................................................................................................................... 8
1.1.2.7 Working Hours ............................................................................................................................. 8
1.1.2.8 Industrial Relations ...................................................................................................................... 8
1.1.2.9 First Aid ........................................................................................................................................ 8
1.1.2.10 Manner of Execution - Personnel ................................................................................................ 8
1.1.2.11 Contractor's Representatives and Personnel .............................................................................. 9
1.1.3 Statutory Requirements, Codes, Building Regulations ................................................................ 9
1.1.4 Project Management ......................................................................................................................... 9
1.1.4.1 General ........................................................................................................................................ 9
1.1.4.2 Contractor’s Representative ...................................................................................................... 10
1.1.4.3 Competence of Welders and other Personnel ........................................................................... 10
1.1.4.4 Welders and Welders Qualification - General ........................................................................... 10
1.1.4.5 Welders’ Test ............................................................................................................................. 11
1.1.4.6 Programming ............................................................................................................................. 11
1.1.4.7 Progress Reports ....................................................................................................................... 11
1.1.4.8 Progress Meetings ..................................................................................................................... 11
1.1.4.9 Project Documentation .............................................................................................................. 12
1.1.4.10 Drawings .................................................................................................................................... 12
1.1.4.11 Calculations ............................................................................................................................... 13
1.1.4.12 Manuals ..................................................................................................................................... 14
1.1.4.13 Plant Identification System ........................................................................................................ 15
1.1.4.14 Procedures ................................................................................................................................. 16
1.1.4.15 Inspection and Tests .................................................................................................................. 17
1.1.5 Site Services .................................................................................................................................... 18
1.1.5.1 General ...................................................................................................................................... 18
1.1.5.2 Water Supply ............................................................................................................................. 19
1.1.5.3 Telephone/Fax ........................................................................................................................... 19
1.1.5.4 Power Supply ............................................................................................................................. 19
1.1.5.5 Sewage System ......................................................................................................................... 19
1.1.5.6 Washing and Sanitary Facilities ................................................................................................. 19
1.1.5.7 Fire Fighting ............................................................................................................................... 19
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1.1.5.8 Personal Protection Equipment ................................................................................................. 19
1.1.6 Quality Assurance ........................................................................................................................... 20
1.1.6.1 General ...................................................................................................................................... 20
1.1.6.2 Quality Assurance, Concept and Control .................................................................................. 20
1.1.6.3 Quality Assurance Manual (QAM) ............................................................................................. 20
1.1.6.4 Works (Manufacturer’s Facilities) Quality Assurance Programme (WQAP) .............................. 21
1.1.6.5 Site Quality Assurance Programme (SQAP) ............................................................................. 21
1.1.6.6 Project Specific Quality Plan (PSQP) ........................................................................................ 22
1.1.6.7 Quality Control Records/Manual ................................................................................................ 23
1.1.6.8 Monitoring by the Employer ....................................................................................................... 23
1.1.6.9 Site ............................................................................................................................................. 24
1.1.7 Safety................................................................................................................................................ 24
1.1.7.1 Contractor’s Obligations ............................................................................................................ 24
1.2. TECHNICAL REQUIREMENTS ............................................................................ 29
1.2.1 Metrological Site Conditions ......................................................................................................... 29
1.2.2 Working Arrangements .................................................................................................................. 29
1.2.2.1 Planning of Work........................................................................................................................ 29
1.2.2.2 Protection of the shell during erection ....................................................................................... 29
1.2.3 Storage Tanks ................................................................................................................................. 29
1.2.3.1 Terminal Points .......................................................................................................................... 29
1.2.3.2 Design Parameters .................................................................................................................... 29
1.2.4 Details of Tanks and Accessories Lots 1 to 2 .............................................................................. 30
4.1.1.1 General ...................................................................................................................................... 30
4.1.1.2 Operational philosophy of Diesel Fuel Oil tanks ........................................................................ 30
1.2.4.1 General ...................................................................................................................................... 31
1.2.4.2 Design Standards ...................................................................................................................... 31
1.2.4.3 Tank Drainage ........................................................................................................................... 31
1.2.4.4 Nozzle Details and Fittings ........................................................................................................ 31
1.2.4.5 Materials .................................................................................................................................... 31
1.2.4.6 Instrumentation .......................................................................................................................... 31
1.2.5 Details of Tank and Accessories Lot 3 ......................................................................................... 34
1.2.6 Corrosion Protection ...................................................................................................................... 36
1.2.6.1 Exterior Paint Protection System ............................................................................................... 36
1.2.6.2 Underside of Tank Floor-plates Paint Protection System ...................................................... 3637
1.2.6.3 Interior Paint Protection System ................................................................................................ 37
1.2.7 Cleanliness, Preparation, Painting, Finishing and Repairs of Painted Surfaces ..................... 37
1.2.7.1 Cleanliness of the System: Treatment of Internal Surfaces ...................................................... 37
1.2.7.2 Protection, Painting, Finishing and Packing .............................................................................. 37
1.2.7.3 Surface Preparation and Conditions for Painting ...................................................................... 37
1.2.7.4 External Tank Painting and Under-floor Plates ......................................................................... 37
1.2.7.5 Internal Tank Painting ............................................................................................................ 3738
1.2.7.6 Priming Coats – Shop Priming Coat ...................................................................................... 3738
1.2.7.7 Post Welding Surface Treatment and Priming .......................................................................... 38
1.2.7.8 Repair of Damaged Paint-work .................................................................................................. 38
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1.2.7.9 Control of Paint Thickness ......................................................................................................... 38
1.2.7.10 Areas for Special Attention .................................................................................................... 3839
1.2.7.11 Compatibility of Paints ............................................................................................................... 39
1.2.8 Pipework .......................................................................................................................................... 39
1.2.9 Tank Labelling ................................................................................................................................. 39
1.2.10 Civil Requirements .......................................................................................................................... 39
1.2.10.1 Materials for Civil Works ............................................................................................................ 39
1.2.10.2 Information for Civil Works ......................................................................................................... 39
1.2.11 Final Information to be Supplied before Contract Completion .................................................. 40
1.3. APPENDICES ....................................................................................................... 41
1.3.1 APPENDIX A – CODES AND STANDARDS ................................................................................... 42
1.3.2 ................................................................................................................................................................. 42
1.3.3 APPENDIX B – ABBREVIATION LIST ............................................................................................ 43
1.3.4 APPENDIX C – SAFETY, HEALTH AND ENVIRONMENTAL ........................................................ 45
1.3.5 APPENDIX D - CORROSION PROTECTION .................................................................................. 47
1.3.6 APPENDIX E - DRAWINGS ............................................................................................................. 48
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1.1. General Requirements
1.1.1 Scope
1.1.1.1 The Development
Ankerlig Power Station is at Atlantis in the Western Cape Province. The project was constructed in
two phases, namely Ankerlig 1 which is 600MWe capacity, 4 x 150MWe gas turbines installed in
separate enclosures and Ankerlig 2 which is 750MWe capacity, 5 x 150MWe gas turbines installed
in one Turbine hall enclosure.
The gas turbines are Siemens SGT5-2000E model which are nominally 150MWe units. The gas
turbines are installed in the form of open cycle and are known as OCGT’s (Open Cycle Gas
Turbines). Eskom generation has identified an urgent need for additional diesel storage tanks at
Ankerlig due to required increased operation of the gas turbines.
The gas turbines were originally installed to operate on Peaking generation, which is morning and
evening peak with the load factor of 3 to 5%. The projected load factor for the gas turbines
operations has gone up to 40% in some months and the existing diesel storage tanks will not meet
with these projected load factors.
This works information is concerned with the additional diesel storage tanks for Ankerlig Power
Station. The additional diesel storage tanks will be considered by the Employer as an extension to
the existing diesel storage system.
1.1.1.2 Permits and Licenses
The Employer is responsible for obtaining all the relevant permits and licenses associated with the
development of the additional diesel storage tanks. The Contractor is responsible for obtaining all
the relevant permits and licenses associated with the construction, installation and commissioning of
the additional storage tanks contract for Ankerlig Power Station.
1.1.1.3 Scope of the Works
The scope of this contract is to carry out the process and mechanical design, manufacture, and
supply, delivery, erection, testing, painting and corrosion protection, commissioning and handover of
storage tanks at Ankerlig Power Station. Tanks are required for the storage of No 2 distillate fuel oil,
and raw fire-fighting water. The scope will be in two lots as follows:
Lot 1 two No 2 distillate fuel oil storage tanks at Atlantis.
Lot 2 one fire water tank at Atlantis.
Civil works including bunds
1.1.1.4 Exclusions
The following Activities are specifically excluded from the works:
Off loading pumps only but not the connecting piping.
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1.1.2 Site Conditions Access and Contractor’s Area
1.1.2.1 Security
The Contractor shall conform to all Site security requirements. Furthermore the Contractor shall be
responsible at all times for the security of his own personnel, equipment and materials and for the
security of their operations within the Site extent.
1.1.2.2 Contractors Compound/Lay-down
A suitable Contractor’s Lay-down Area is made available to the Contractor. The Contractor shall be
responsible for preparing, stoning, servicing and rendering secure such area of this lay-down area,
which he deems necessary for his storage and accommodation requirements.
The Contractor shall provide any covered storage accommodation and Site offices required for his
materials equipment and workforce. The Contractor shall keep his area clean and tidy and shall
remove all waste and surplus material daily.
It is the responsibility of each Contractor to fence its own lay-down area as deemed necessary inside
the Contractor’s lay-down Area. It is the responsibility of the Contractor to determine whether he
requires security for his lay-down Area and provide if required.
The Contractor shall, before commencing work, submit details of all buildings he proposes erecting
in the Contractor’s lay-down Area and the Construction Site for storage, workshop and offices for the
Project Manager’s approval.
At the end of the Contract, the Contractor shall remove all sheds, offices, toilets, surplus materials
etc., remove all temporary connections and leave the Site in a tidy and safe condition.
1.1.2.3 Car Parking
Car parking shall be provided. No car parking shall be permitted in other areas or on Public Roads.
Construction vehicles are allowed on Site however a permit is required from the Project Manager.
For offloading the Contractor shall be confined to its own lay-down area.
1.1.2.4 Roads
The Contractor shall ensure that existing roads are used with due regard to maintaining their current
condition and any damage whatsoever caused by the Contractor shall be immediately repaired to
the satisfaction of the Project Manager.
The Contractor shall take adequate care to ensure no spillage’s occurring onto the public roads
during transportation of materials to/from the Site. Any debris/spillage’s that occur on the public and
Site roads shall be the responsibility of the Contractor and shall be immediately removed/cleaned
up. With regard to prevention of any deposition of muck, dirt etc on roads, the Contractor shall make
all provisions necessary for the cleaning of vehicles leaving the Site.
1.1.2.5 Co-operation with Other Site Service Providers/Good Neighbours Policy
1.1.2.5.1. General
The Contractor shall arrange his operations in such a way as to avoid causing interference and to
minimise disturbance to other staff and to the users of the Site and public roads. The Contractor
shall ensure that the works carried out do not interfere with the operation of the Ankerlig Power
Station except where such interference is deemed unavoidable and is approved by the Project
Manager. Permits will be required for access to the existing Ankerlig 1&2 plants.
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1.1.2.5.2. Other Service Providers
The Contractor’s attention is drawn to the fact that there shall be other service providers who will
require access along routes which will be subject to construction activities. This will require co-
operation with the Project Manager by all relevant parties to ensure that disruption to all contracts is
minimised.
1.1.2.5.3. Good Neighbours
The project has a good neighbour’s policy. This means that any inconvenience caused by the Site
operations to people who work or live in the vicinity shall be minimised.
The Contractor shall take all precautions to avoid the creation of noise, dust, noxious smells,
offensive behaviour or other pollution on the Site. The Project Manager may at his discretion
prohibit any activities, which breach the spirit of this intent.
1.1.2.6 Site Cleanliness
The Contractor shall at all times keep his work and storage areas clean and tidy and at regular
intervals, which shall not exceed a week, shall remove all waste or surplus material and arrange and
pay for disposal off Site. The Contractor shall provide adequate skip facilities around the Site for
waste disposal. The Contractor shall safely clear the Site of temporary structures, surplus material,
equipment, fuel, all liquids and erection equipment and tools on completion.
Where the Contractor fails to meet these requirements, the Employer may remove materials from
Site and charge resultant costs to the Contractor.
1.1.2.7 Working Hours
The Contractor shall comply with the working hours on Site unless otherwise agreed with the Project
Manager.
The working hours for the Site are between the following hours:
06.00 – 18.00 Monday to Friday
06:00 – 13:00 Saturday
1.1.2.8 Industrial Relations
The Contractor shall comply with all local statutory and other labour laws and regulations pertaining
to the Works.
1.1.2.9 First Aid
The Contractor complies with all statutory requirements in addition to the requirements of this
Specification.
1.1.2.10 Manner of Execution - Personnel
During the erection of the Works, the Contractor (or Sub-Contractor) shall pay the wages for any
local labour, skilled or unskilled, employed by him and shall comply with the working hours and
holidays appropriate to the district and with the Basic Conditions of Employment Act.
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1.1.2.11 Contractor's Representatives and Personnel
The Contractor shall appoint a Site Manager from the date of commencement of the Construction
Work on the Site. The Site Manager shall be responsible for the organisation and co-ordination of
the entire installation and shall be authorised to make binding arrangements.
The Contractor should supply a full time safety representative. The Contractor’s Safety
Representative is required to attend all safety meetings on Site.
The Contractor shall provide on the Site adequate changing facilities for his workforce suitably
equipped with lockers, changing facilities and toilets and shall provide for adequate attendance to
maintain the facility.
1.1.3 Statutory Requirements, Codes, Building Regulations
The Contractor shall be required to assume full professional liabilities with regard to fulfilment of any
Statutory Requirements. In this regard, the Contractor is advised to acquaint himself thoroughly with
the local statutory regulations and requirements in the Republic of South Africa together with
relevant data/undertakings contained in the approved documents.
Codes and standards governing the design, construction, commissioning and testing of the Plant
must be accepted by the Project Manager. The Plant and each individual portion thereof must
comply with internationally accepted codes and standards.
In case of conflict between international codes, standards or guidelines and the requirements
specified in this Functional Specification, the more onerous specification takes precedence.
As a minimum requirement the contractor shall comply with all legislation and mandatory codes and
standards.
1.1.4 Project Management
1.1.4.1 General
Further to the NEC requirements the Contractor shall submit a Project Implementation Plan (PIP) for
acceptance which shall not materially deviate from that submitted with the tender. Any deviations will
be subject for acceptance by the Project Manager.
The Contractor shall submit organisation charts to indicate the relationship of the project
management team to the Contractors overall organisation and shall identify the person with overall
responsibility, authority and control. The Contractor shall prepare a Project Management Manual
setting forth the responsibilities and levels of authority within the Project Management Team and
Contractors organisation chart.
Names and curriculum vitae of other key personnel including designers shall be submitted to the
Employer by the Contractor. It is a requirement that the key personnel, in particular, have good
communication skills in the English language. Key personnel shall be appointed to the acceptance of
the Project Manager.
Any Contractor or sub-Contractor personnel deemed by the Project Manager to be incompetent,
negligent or otherwise objectionable shall be removed from the jobsite or design/manufacturing
phase immediately upon the request of the Project Manager. Key personnel shall not be replaced
without the approval of the Project Manager.
It shall be a requirement that key personnel of the Contractor’s Project Management Team provide
continuity in the control of the Works until the end of the warranty period.
Any Contractor or sub-Contractor personnel deemed by the Project Manager to be incompetent,
negligent or otherwise objectionable shall be removed from the jobsite or design/manufacturing
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phase immediately upon the request of the Project Manager. Key personnel shall not be replaced
without the acceptance of the Project Manager.
It shall be a requirement that key personnel of the Contractor’s Project Management Team provide
continuity in the control of the Works until the end of the warranty period.
The Contractor shall prepare and implement a document management system, for receiving,
distributing, and retaining project correspondence, design data, drawings, specifications, instruction/
data books, test reports, progress reports etc.
Data books for each system shall contain the following:
Complete set of as built drawings.
All quality documents.
Completed Quality Control Plans.
All test results (including material mill certificates, welding maps, pump test curves, electrical
equipment tests, etc.)
All equipment specifications.
Operating and maintenance manuals.
The final master document shall be handed over to the Project Manager.
The Contractor shall implement and keep up to date a configuration management plan (including
KKS coding).
1.1.4.2 Contractor’s Representative
The Contractor shall appoint a person at the date of signing the Contract (The Contractor’s
Representative) who will have full responsibility for the complete Works and act as a single point of
contact in all matters on behalf of the Contractor.
The Contractor's Representative shall be responsible for the organisation and co-ordination of the
entire installation and for clarification of all pending installation questions with the Project Manager
and the Contractor's Representative shall be authorised to make binding arrangements.
The Contractor shall supply a full time safety representative who has responsibility for carrying out
all safety tasks. The Contractor’s Safety Representative is required to attend all safety meetings on
site.
1.1.4.3 Competence of Welders and other Personnel
The Contractor (or Sub-Contractor) shall employ, for execution of the Works, only personnel
possessing a level of competence, skill and (where called for) qualification which is adequate for the
tasks assigned to them.
For welding operations each welder shall possess a valid certificate of competence as specified in
the appropriate design or construction code. Before commencing any work on the Site, this
certificate must be produced for inspection by the Employer. The Contractor shall have valid and
current welder qualifications certificates appropriate for the welding to undertaken by each of the
Contractors or subcontractors welders.
1.1.4.4 Welders and Welders Qualification - General
Welders employed on any work under the Contract, either at manufacturers facilities or on site, shall
be proved to be competent to carry out the type and standard of welding required prior to
commencing work. All welders shall be qualified in accordance with EN 287 or approved equivalent,
international standard.
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In the case of pressure parts and pressure part attachment welds, each approved welder shall have
a unique identification number which shall be indicated on all welds made by him and on all
permanent test records applicable to those welds including radiographs.
All welders engaged on either shop or site welding shall be under the supervision of a competent
welding engineer. The Contractor shall submit details of his control procedures for welding, heat
treatment and non-destructive testing as part of the quality control procedures.
1.1.4.5 Welders’ Test
Sample welds shall be carried out on specimens of similar shape, thickness and chemical analysis
to the material to be welded, and in a position which shall represent as far as possible the worst
conditions under which actual welding will take place. The method of preparation of the test pieces,
and the standards to be used in examination of them shall be according to the agreed Standard or
Codes, or as may be agreed with the Employer’s Representative. All expenses in connection with
welder's tests shall be borne by the Contractor. The range of approval shall cover all welds to be
undertaken by the welders.
1.1.4.6 Programming
The Contractor shall appoint a fully experienced scheduler competent in the use of Primavera P5 to
undertake all programming for the complete Works for the period of the contract. The scheduler will
transfer to site and be located on site during the installation and commissioning of the plant.
Programming shall be in accordance with Clause 31 of the NEC Engineering and Construction
Contract.
The Contractor shall furnish a detailed programme and critical path analysis indicating each
separate operation in the works. The Contractor’s programme and critical path analysis shall be
processed at least monthly throughout the Contract.
In addition, the Contractor shall furnish to the Project Manager each week a detailed statement of
the work he proposes to carry out each day of the following week.
1.1.4.7 Progress Reports
The Contractor shall be required to furnish progress reports in accordance with Clause 32 of the
NEC Engineering and Construction Contract. In addition, the Contractor shall be required from time
to time to estimate final and intermediate (e.g. delivery) dates. Relevant photographs of construction
progress shall be included with the Project Report.
The progress of the entire project will be controlled using a critical path analysis programme.
The Contractor will be required to furnish weekly and monthly progress reports against approved
programmes, in a format approved by the Project Manager.
1.1.4.8 Progress Meetings
The Contractor shall be required to have regular progress meetings at intervals to be agreed, but at
a minimum of monthly with the Project Manager.
During the design, engineering, procurement and manufacturing phases, progress and design
review/clarification meetings shall be held with the Project Manager on an as needed basis, but as a
minimum once a month.
When construction / commissioning activities commence, progress meetings shall be held monthly
on Site, supplemented by weekly (or as required) site meetings to review progress and
measurements of site activities. The Contractor shall appoint an experienced planner to the Site
from commencement of construction on Site for the duration of major construction work.
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At any stage during the Contract special meetings may be arranged as necessary to resolve any
technical or commercial issues. Each party shall pay their own travel and accommodation expenses
for the meetings.
It is the Contractors responsibility to organise Progress Meetings and to issue Minutes of Meeting.
1.1.4.9 Project Documentation
1.1.4.9.1. Submission of Project Documentation
The Contractor shall provide within one (1) month from the Contract Date a complete time schedule
for submission of all documentation including drawings, methodologies, design calculations,
schematics, wiring tables/diagrams, manuals, procedures and any other information.
It is an essential requirement that all documentation and any other information shall be submitted to
the Project Manager at a specified date and in sufficient time for acceptance before proceeding with
the relevant part of the work. In particular all drawings, operating philosophy, control philosophy,
design philosophies and design calculations shall be submitted at regular intervals to ensure a
steady flow of submissions. Acceptance may be delayed if large quantities of documentation are
submitted at the one time.
Acceptance by the Project Manager will not relieve the Contractor of his obligation to meet all the
requirements of the Contract or relieve the Contractor of his responsibility for adequacy of design
calculations and drawings and other documentation.
All project documentation shall be transmitted electronically in addition to three hardcopies.
If the Contractor provides drawings which are common to multiple units / systems / items of plant the
Contractor shall put in place a programme to ensure that any differences are highlighted and
documented on all relevant drawings (including as-built), procedures & instructions specific to each
unit.
Configuration management will be implemented to ensure that all documents are kept up to date and
reflect the as-is and as-built status.
1.1.4.10 Drawings
1.1.4.10.1. Contract Drawings
Three (3) hardcopies of all drawings plus one (1) electronic copy shall be submitted in sufficient time
to permit comment and/or modifications being made without delaying the Contract Delivery and
Completion Dates. For key drawings, the Project Manager reserves the right to request additional
copies.
Within one (1) month of Contract Date, the Contractor shall submit a detailed Master Drawing
Schedule in EXCEL or other approved format, showing each drawing, including subcontractors’
drawings, and the date for submission of these drawings for acceptance by the Project Manager.
Columns will be provided in this schedule for the following information:
Date of submission to the Project Manager.
Date on which Project Manager Comments are received.
Dates of re-submission and further comments if applicable.
Dates on which drawings issued for construction.
Dates on which drawings subsequently revised.
Date on which drawings issued in as-built form.
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This Master Drawing Schedule shall be updated and submitted to the Project Manager for
acceptance. A copy of the updated Master Drawing Schedule shall be included with the Progress
Report.
Following completion of construction of the tanks the Contractor shall submit “As–built” drawings for
the Project Manager’s acceptance. The accepted drawings shall be duly stamped “As-built”.
1.1.4.10.2. Construction Drawings
Construction drawings shall include fully dimensioned arrangement and detail drawings giving the
design code, operational and design pressure and temperature and the ratings, scantlings and
materials of all components. Weld details and applicable WPS shall be included and any specific
construction and manufacturing procedures. All non destructive examination and hydrostatic testing
requirements shall also be given.
1.1.4.10.3. Preparation and Format
All drawings supplied under the Contract shall have titles and explanatory notes in English. In
addition, English translations of any Standard, Specification or Document related to the design,
production, inspection or testing of any part of the Works shall be supplied.
The drawings shall be prepared in accordance with a recognised international or national standard
and include a title block accepted by the Project Manager. For hard copies of drawings ISO “A”
sizes shall be adhered to and except in special circumstances, sizes larger than “A1” shall not be
used.
Drawings shall preferably be supplied in Microstation format and copies of all drawings shall be
provided on CD-ROM or other suitable computer media.
1.1.4.11 Calculations
1.1.4.11.1. Submission of Calculations
All design calculations shall be submitted to the Employer for information.
1.1.4.11.2. Presentation of Calculations
Calculations must be comprehensive, coherent and suitably referenced to information sources and
cross referenced within themselves. All calculations, other than computer printout, shall be on A4
size paper properly bound. Each book of calculations shall have a title page. The title page shall
indicate clearly:
Contractor’s name.
Project name.
Designer’s name.
Checker’s name.
Contract number.
Calculation title.
Assumptions used for design purposes including reference to Basic Design Criteria Document.
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Codes and Standards used.
Loadings used (where applicable).
Date of Calculation.
Calculation.
Reference sources
Manufacturer’s names and literature.
Reference to the appropriate drawing.
Technical specification section and paragraph number.
Control register reference as applicable.
Date of issue.
The title page shall also provide for the recording of any revisions (and dates) to the calculations.
Calculations shall be in English and in SI units, clearly legible, preferably typed and bound in stiff-
backed ring binders. Calculations which are not easily legible or which present difficulty in
comprehension will not be accepted by the Project Manager and the Contractor shall be obliged to
resubmit such calculations in legible/comprehensible form for acceptance by the Project Manager.
The Contractor shall provide a master design schedule in Microsoft Excel format which will be
updated on a monthly basis. It will have columns showing dates for submission by the Contractor
and comments by the Project Manager as required in Sub-section 1.1.4.10 for Calculations. A copy
of the updated Master Design Schedule shall be included with the Progress Report.
1.1.4.12 Manuals
The Contractor shall provide four (4) hardcopy sets of the manuals for each station to enable the
Project Manager to comment and request changes as necessary. Copies of all Manuals shall also
be provided on CD-ROM or other suitable computer media marked for review. The final version (as
built) of all Operations and Maintenance (O&M) manuals shall be provided four (4) months after
taking over of the plant, marked final version.
In all cases, and irrespective of hard copies supplied, electronic copies of manuals are required in a
Microsoft / .pdf format suitable for use with Eskom’s user software standards.
All manuals shall be divided by systems or sections and cross indexed as necessary.
The number of copies required is four (4).
The manuals are complete with:
power station name and order number;
content list;
list of reference drawings;
details of all components
The manuals are submitted in loose-leaf binders to ISO format and normally A4 size. The use of
oversize pages is kept to a minimum and does not exceed page height unfolded. Fixings are
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preferably “D” ring and are of the snap close type. Post binders or other fixings are not acceptable.
Binders do not exceed 80mm in overall thickness. The document identity appears on both the front
cover and on the spine.
Manuals are of good quality prepared by suitably experienced personnel and contain general
arrangement drawings, installation drawings and instructions, operating and maintenance
instructions for all components, detailed parts lists which are accompanied by exploded view type
drawings clearly detailing the part and uniquely identifying it, technical descriptions of the plant and
material and component parts, spare part ordering instructions and type test certificates. Any special
instructions pertaining to storage of spare parts or to their shelf life are included in the manual.
All drawings required for component location, dismantling, and re-assembly for maintenance is
provided in the manual. All special tools required for maintaining and operating the plant and
material are identified in a schedule and described in the manual.
Manuals are produced such that a Synopsis is first presented, followed by a First Draft, then a pre-
print Proof and finally by the Approved Manual. The required documents are submitted for
acceptance on the dates as shown in the key date schedule.
1.1.4.12.1. Design Manual
This manual shall contain all the design calculations and all equipment and system data sheets and
design criteria required under the Contract.
1.1.4.12.2. Construction Manual
This shall include a comprehensive record of as built site construction tests and records. The
manual(s) shall be compiled in separate parts to reflect the plant and services supplied.
1.1.4.12.3. Commissioning Manual
This manual shall include all the records, certificates and test results arising from the agreed pre-
commissioning and commissioning procedures carried out on site. The performance tests and
guarantee test results shall also be included. There is a particular requirement that all commissioned
plant/equipment values be recorded in this manual and subsequently incorporated into the final
version of O&M manuals.
1.1.4.12.4. Quality Assurance Manual (QAM)
Refer to section 1.1.6.3 in this document.
1.1.4.12.5. Quality Control Records/Manual
Refer to section 1.1.6.7 in this document.
1.1.4.13 Plant Identification System
A common alphanumeric designation system for the codification of all items of plant, equipment and
components shall be used for the whole power station. The coding system is based on the
“Kraftwerk Kennzeichen-System” (KKS), as developed by the VGB (Germany) and adapted for
Eskom. The Contractor shall be responsible for ensuring that he is fully familiar and compliant with
the standards and concepts of the KKS system as applied by Eskom.
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The Contractor shall be responsible for the codification of all plant, equipment and components in his
supply for which he is responsible in terms of engineering and design.
The specific KKS-code of each item of plant, equipment, component, measuring points, junction box,
cable, etc., shall appear on all documents, instruction manuals, schedules, drawings (i.e. flow
diagrams, general arrangement, schematic diagrams, cable block diagrams, etc.) and labels for
plant, equipment and components.
A list of all KKS codes used by the Contractor shall be provided in accordance with Eskom standard
documentation. The relevant KKS-code shall be included on the label according to the required
Eskom standard format.
The allocation of all codes shall be to Eskom approval. The Contractor shall ensure that the code is
applied in a uniform and consistent way and that all codes allocated are unique.
1.1.4.14 Procedures
1.1.4.14.1. Weld Procedures, Specifications and Documentation
For all pressure pipelines, containment vessels, and structural welded items, the Contractor shall
submit to the Project Manager for comment, the following documents prior to commencement of
welding:
Welding Procedure Specification (WPS).
Weld Procedure Approval Records (WPAR).
Welder Qualification Records (WQR).
Pre- and Post- Weld Heat Treatment where applicable.
Inspection Schedule including Quality Assurance and Quality Control Requirements.
Third party inspection authorities and / or authorised bodies.
Non-destructive Examination and Testing Procedures.
Standard Weld Repair Procedures.
All welding procedures including those proposed in repair situations shall be qualified as required
EN288 or approved equivalent and all qualified procedures shall be submitted to the Project
Manager for acceptance prior to the commencement of any welding.
Tube ends shall be prepared in accordance with an internationally recognised standard for welding
tube to tube, tube to wall and tube to headers, etc.
Inspection records will be stored on site and available in a coherent and traceable manner when
required.
1.1.4.14.2. Welding Electrodes and Consumables
Before any welding is commenced, the Contractor shall submit a list of all electrodes and
consumables to be used, to the Project Manager for acceptance. In each case, the appropriate DIN,
BS, ASTM or equivalent designation together with the proprietary brand name shall be given.
Welding electrodes shall be suitably stored before use.
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1.1.4.14.3. Site Welding
The Contractor shall be required to establish the procedures and conduct the tests, or provide the
evidence required, according to the agreed Welding Code to qualify the procedures, for use with the
agreed Construction Code and the welders for the application of the procedures.
1.1.4.14.4. Erection Procedures
The Contractor shall submit four (4) sets of the erection procedures for each tank to the Employer for
information so as to allow the Project Manager to comment one (1) month prior to the referenced
erection commencing on Site.
1.1.4.14.5. Pre-Commissioning and Commissioning Procedures
The Contractor shall prepare four (4) sets detailed testing and pre-commissioning procedures to
cover the period from completion of erection to ready to start-up and all commissioning tests and
procedures to be carried out to achieve readiness for performance testing. These procedures shall
be submitted to the Project Manager two (2) months prior to commencement of the pre-
commissioning.
1.1.4.14.6. Performance and Guarantee Tests Procedures
The Contractor shall submit the performance and guarantee tests procedures to the Employer for
comment, at a date to be agreed, but not less than two (2) months prior to start of commissioning.
1.1.4.15 Inspection and Tests
1.1.4.15.1. Materials
All construction materials will be new and clean and will be free from rust and pitting and the cast
numbers will be clearly marked. Material cast numbers will be checked for compliance with the
material certificate and the requirements stipulated on the drawings.
Manufacturer’s material certificates of chemical analysis and mechanical properties shall be
submitted for all material used in the Works or as otherwise accepted by the Project Manager.
Materials are to be accepted by the Project Manager. Where a test piece fails to comply with the
relevant material specification or the material cast number indicates a material not compliant with the
material stipulated on the drawings the Project Manager reserves the right to reject the whole of
such material. Materials proposed for use are subject to the approval of the Project Manager. The
Project Manager may reject the materials at his absolute discretion.
1.1.4.15.2. Inspection of Welding
The extent of weld inspection, the final weld quality, and the method of examination shall be as
stated in the agreed Standards or Codes. All welding inspection shall be performed by Welding
Inspectors that are qualified to perform inspections. The Contractor shall maintain, both at the
manufacturer facilities and on site, adequately indexed records of all welding, weld inspection and
repairs which shall be available to the Project Manager, together with light box facilities and dark
room for viewing of X-ray radiographs.
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1.1.4.15.3. Weld Repairs
The Contractor shall immediately advise the Project Manager of any repair required on the Works.
Where such repairs are found to be necessary by welding, dimensioned sketches of the excavated
areas shall be prepared and the proposed repair procedures submitted for acceptance by the Project
Manager before any repair is undertaken.
In the case of weld cracking, the Project Manager shall require a full investigation to be made to
establish the cause of cracking. No repair work or removal of the evidence shall be undertaken prior
to acceptance of the repair procedures by the Project Manager. The cost of all such investigations
and reports shall be wholly borne by the Contractor.
1.1.4.15.4. Non-Destructive Tests
All welds shall be tested in accordance with the relevant standards accepted by the Project
Manager. This is a minimum requirement and in no way limits the Contractor’s overall responsibility
for quality of fabrication.
1.1.4.15.5. Pressure Tests
The Contractor shall hydraulically test all parts subjected to internal pressure under normal or
abnormal working conditions after satisfactory completion of the other non-destructive tests in
accordance with the applicable codes. The Contractor shall be required to perform a Hydro-test and
shall include all fittings and hoses for this purpose.
Hydraulic test pressures quoted shall in all cases be the difference between internal and external
pressures and in each test, the test pressure shall be maintained for sufficient duration to allow a
thorough inspection of all seams, joints and connections; but in no case shall a test of less than that
specified in the API650 standard. The Contractor will supply all equipment, suitably calibrated, to
perform these tests. Water will be made available to the Contractor for the purpose of the hydro-test.
The contractor shall demarcate and appropriately make safe the area surrounding the tank during
hydraulic tests.
A hydro-test procedure and programme will be submitted to the Project Manager for acceptance
prior to a test being carried out.
1.1.4.15.6. Low Pressure Pneumatic Leak Testing
The Contractor shall include for pneumatic testing of all reinforcement plates used.
1.1.4.15.7. Third Party Inspection
The Contractor shall provide for a third party inspection of pressure systems. This inspection should
include for the review of the design, welding and erection procedures and a review of the NDT
results of the welds. The third party Inspection Company should provide certification that the work is
complete, to their satisfaction and meets all statutory requirements.
1.1.5 Site Services
1.1.5.1 General
The Contractor shall provide all necessary services at the required locations.
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1.1.5.2 Water Supply
The Employer will provide a construction water supply at a source within the Site boundary The
Contractor shall be entirely responsible for providing his own water supplies in the Contractor’s Area.
It is the responsibility of the Contractor to make an agreement with the Employer for the supply of
water to the Contractor’s Area.
1.1.5.3 Telephone/Fax
The Contractor shall be entirely responsible for providing his telephone connection in the
Contractor’s Site office area The Contractor shall bear all charges associated therewith including
payments for the supply of services.
1.1.5.4 Power Supply
The Employer will provide a construction power supply to the site boundary. The Contractor shall be
entirely responsible connecting to this source and routing the cables as required by the Project
Manager. The Contractor shall indicate the extent of supply required.
The Contractor shall bear all charges associated therewith including payments for the supply of
services.
All wiring and electrical work carried out by or on behalf of the Contractor shall conform to the
Employer's regulations, be maintained in a proper condition, and be to the satisfaction of the Project
Manager.
1.1.5.5 Sewage System
The Employer will provide appropriate connection to the sewerage system in the site area.
1.1.5.6 Washing and Sanitary Facilities
The Contractor will provide all provisions necessary for washing and sanitary facilities to conform to
Statutory Health and Safety requirements.
1.1.5.7 Fire Fighting
The Contractor shall provide adequate fire fighting provisions for their construction area. Fire
extinguishers shall be provided by the Contractor in the work areas and his staff shall be trained in
their use. The Contractor shall comply with recommendations provided in NFPA 850 for fire
protection during construction.
The Contractor shall ensure that there is no interference by his employees or by his sub-Contractors
with the ring main and equipment other than for use in fire fighting. He shall arrange that in all areas
under his control the recommended type of fire extinguishers shall be properly identified by suitable
markers and regularly serviced.
1.1.5.8 Personal Protection Equipment
Protective equipment of an appropriate type and standard shall be worn by all persons without
exception while on site. Minimum shall include safety helmet and footwear, and, where necessary,
ear protectors and eye protection glasses.
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1.1.6 Quality Assurance
1.1.6.1 General
The Contractor shall for all the Works to be performed have established and implement quality
assurance arrangements which meet the requirements set out in the International Standard ISO
9001:2000 “Quality Management System, which shall include, in a transparent manner, the quality
assurance and quality control of its sub-contractors during all phases of the Contract, including,
Design and Engineering, manufacturing, Site Construction, Erection, Commissioning and Start-up.
The Contractor shall check all parts of the Works before dispatch from the manufacturing facilities to
ensure that all materials, dimensions and tolerances are in accordance with certified drawings and
mill certificates.
1.1.6.2 Quality Assurance, Concept and Control
This section provides the minimum requirements for establishing and implementing a quality
assurance programme which is applied to all aspects of the work necessary for carrying out the
Contract.
The scope of this section extends to material parts, components, systems and services as a means
of obtaining and sustaining the reliability of critical items, operating capacity and availability. If the
Contractor’s programme does not cover the quality assurance requirements as indicated in this
section then he must state, together with documentary evidence, the reason why the requirements
do not apply.
Acceptance of the Contractor’s quality assurance programme does not relieve the Contractor’s
obligation to comply with the requirement of the Contract. If the programme is found to be ineffective
or inadequate in providing for quality assurance or control, then the Project Manager reserves the
right to request for necessary revisions of the programme.
The Contractor is required to produce readily identifiable documentary evidence covering the extent
and details of both his own and his subcontractor’s quality assurance system.
The documentary evidence should take the following form:
Quality Assurance Manual (QAM)
Works (Manufacturer’s Facility) Quality Assurance Programme (WQAP)
Site Quality Assurance Programme (SQAP)
Project Specific Quality Plan (PSQP)
While acknowledging that the Contractor may combine the QAM, WQAP and SQAP as one
document, it is a specific requirement of this Specification that these documents are prepared
separately and submitted to the Project Manager.
1.1.6.3 Quality Assurance Manual (QAM)
The QAM shall be a general comprehensive document outlining the Contractor's basic organisation,
policies and procedures. The information to be given in the QAM shall include but not be limited to:
Quality policy
Quality assurance programme
Organisation structure showing inter-relationships
Functional responsibilities and levels of authority
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Lines of communication
Customer relations
Laboratory facilities
Design review
1.1.6.4 Works (Manufacturer’s Facilities) Quality Assurance Programme (WQAP)
The WQAP shall detail the Contractor's quality assurance programme at Works applicable
throughout all phases of Contract performance including design, procurement, manufacture,
inspection and testing. It shall identify each of the programme elements to be designed, developed,
executed and maintained by the Contractor for the purpose of ensuring that all supplies and services
comply with this Specification including the Employers requirements.
The information to be given in the WQAP shall include typically:
Organisation and responsibility
Design and document control
Procurement control
Control on sub-Contractors
In-process quality control
Welding quality control
Heat treatment control
Inspection and testing
Control of non-conformances
Corrective action
Control of inspection, measuring and test equipment
Handling, storage and delivery
Records
Quality audits
1.1.6.5 Site Quality Assurance Programme (SQAP)
The SQAP shall detail the Contractor's Quality Assurance Programme at Site applicable throughout
site construction, erection and commissioning. It is the underlying philosophy of this Specification
that the quality built into the product at Works shall be maintained throughout the construction and
commissioning stages. The quality and workmanship shall be consistent with the design life of the
Works.
While, in principle, the SQAP shall include the items listed in WQAP, it shall, however be
approached differently to take into account site conditions.
The SQAP shall include typically:
Organisation and Responsibility.
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Control of Drawings and Documentation.
Site Activities Checklists.
Cleaning and protection procedures.
Health and Safety management procedures and records.
Receipt Inspection of Materials at Site.
Material Storage Control.
Issue of Materials and Consumables.
Inspection and testing Procedures.
Welding Quality Control.
Non-Destructive Testing.
Heat Treatment Control.
Control of Painting and Insulation Works.
Earthworks control checks and testing.
Concrete Quality Control incl. all test results.
Pre-commissioning.
Commissioning.
Corrective Action.
Control of Inspection, Measuring and Test Equipment.
Records.
Quality Audits.
1.1.6.6 Project Specific Quality Plan (PSQP)
The Contractor is required to prepare manufacturing and site construction / erection quality plans for
all plant items and services provided under the Contract based on the Contractor's standard quality
assurance procedures. The quality plan shall also define the involvement of the Contractor, the
Project Manager and or his inspection authority in the inspection and test programmes.
The Project Specific Quality Plan (PSQP) shall incorporate typically:
Charts indicating flow of materials, parts and components through manufacturing quality control,
inspection and test to delivery and site erection quality control, inspection and test.
The Charts shall indicate the location of hold points for quality control, inspection and test
beyond which manufacture and site erection shall not continue until the action required by the
hold point is met and the documentation required is generated.
Document control procedure.
An indication of the organisations responsible for the quality activities covered and the
responsibilities of the quality assurance personnel.
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Reference to quality assurance procedures, goods inward procedures and non-conformance
procedures, etc.
The Contractor shall review and submit his sub-Contractor's quality plans and include these in the
PSQP. The Contractor shall determine and agree with the Project Manager the control to be
exercised over the sub-Contractors and the degree of surveillance that shall take place.
Provision shall be made for the Project Manager to insert hold points at which quality control
activities are to be witnessed by the Project Manager himself or his appointed inspecting authority.
The Contractor shall furnish the Project Specific Quality Plan (PSQP) not later than one (1) month
prior to the start of manufacture. The PSQP shall define the Contractor's organisation and
responsibilities of all management including quality assurance personnel and shall detail the
procedures the Contractor intends to use to manage and control those aspects of the Works which
may affect the quality of the completed installation.
The PSQP as revised to incorporate any comments of the Project Manager shall be considered as
forming part of the Contract and any subsequent changes must be agreed in writing by the Project
Manager prior to implementation.
The Contractor shall implement effective planning, resourcing and control of all contracted activities
by the implementation of the PSQP and associated work instructions.
The Contractor shall identify its verification requirements on the PSQP submitted to the Project
Manager for acceptance and shall identify the following:
Stages subject to random surveillance,
Inspections to be witnessed,
Hold points beyond which work cannot proceed before completion of all verification and
related activities.
The Contractor shall establish measures for the identification and control of materials and
components throughout all stages of the Contract.
The Contractor shall be responsible for identifying and arranging any verification activities requiring
statutory approval in the country of manufacture.
1.1.6.7 Quality Control Records/Manual
The Contractor shall maintain and provide at the end of manufacture and Works testing a manual or
manuals including copies of all formal certificates, reports and results of tests and inspections
related to the plant covered by the specification. This manual shall contain the approved Works
certification documentation for all Plant, Equipment and services as specified in the relevant codes
and standards and in this specification and the Contractors Quality Manual. This manual shall also
include all mill and material test certificates. Certificates and test procedures shall be specific to the
Plant supplied. Weld procedure and welder qualification certificates shall also be included. Three
sets shall be provided.
1.1.6.8 Monitoring by the Employer
The Project Manager reserves the right to review and amend the proposed verification arrangements
in cases where these arrangements have not been agreed prior to the order date between the
Contractor and any Sub-Contractor / Supplier.
During the course of the Contract the Project Manager reserves the right to monitor the
implementation of the Contractors quality assurance arrangements including those of the Sub-
Contractors; where non conformances are identified the Contractor shall implement agreed
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corrective actions. The Project Manager shall be afforded unrestricted access to review the
implementation of the corrective actions. A programme shall be established for all such audits.
1.1.6.9 Site
For Site work the Project Manager shall monitor all aspects of the Contractors daily work including
his control of Sub-Contractors in accordance with the agreed procedures, compliance with Codes
and Standards and the Specification, Construction Health and Safety plan and the achievement of
milestone dates for the discrete work packages.
1.1.7 Safety
1.1.7.1 Contractor’s Obligations
In carrying out its obligations to the Employer in terms of this contract; in providing the Works; in
using Plant, Materials and Equipment; and while at the Site for any reason, the Contractor complies
and procures and ensures the compliance by its employees, agents, Subcontractors and
mandataries with:
the provisions of the Occupational Health and Safety Act 85 of 1993 (as amended) and all
regulations in force from time to time in terms of that Act (“the OHSA”); and
South African Building Codes and Construction Regulations 25207 of 2003; and
Labour Relations Act; and
the Eskom “Safety, Health and Environmental Requirements for Contractors” document attached
to the Works Information (as amended from time to time) and such other Eskom Safety
Regulations as are applicable to the Works and are provided in writing to the Contractor
(collectively “the Eskom Regulations”). The Eskom Regulations may be amended from time to
time by the Employer and all amendments will be provided in writing to the Contractor. The
Contractor complies with the provisions of the latest written version of the Eskom Regulations
with which it has been provided; and
the health and safety plan prepared by the Contractor in accordance with the SHEQ
Requirements.
(The OHSA and the Eskom Regulations are collectively referred to as the “SHEQ Requirements”.)
The Contractor, at all times, considers itself to be the “Employer” for the purposes of the OHSA and
shall not consider itself under the supervision or management of the Employer with regard to
compliance with the SHEQ Requirements, the Contractor shall furthermore not consider itself to be a
subordinate or under the supervision of the Employer in respect of these matters. The Contractor is
at all times responsible for the supervision of its employees, agents, Subcontractors and
mandataries and takes full responsibility and accountability for ensuring they are competent, aware
of the SHEQ Requirements and execute the Works in accordance with the SHEQ Requirements.
The Contractor ensures that all statutory appointments and appointments required by any Eskom
Regulations are made and that all appointees fully understand their responsibilities and are trained
and competent to execute their duties. The Contractor supervises the execution of their duties by all
such appointees.
The Employer, or any person appointed by the Employer, may, at any stage during the currency of
this contract:
conduct health and safety audits regarding all aspects of compliance with the SHEQ
Requirements, at any off-site place of work, or the site establishment of the Contractor;
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refuse any employee, Subcontractor or agent of the Contractor access to the premises if such
person has been found to commit an unsafe act or any unsafe working practice or is found not to
be qualified or authorised in terms of the SHEQ Requirements;
issue the Contractor with a stop order should the Employer become aware of any unsafe
working procedure or condition or any non-compliance with any provision of the SHEQ
Requirements.
The Contractor immediately reports any disabling injury as well as any threat to health or safety of
which it becomes aware at the Works or on the Site to the Project Manager.
The Contractor appoints a person, qualified in accordance with the SHEQ Requirements, as the
liaison with the Eskom Safety Officer for all matters related to health and safety, this person shall be
contactable 24 hours a day.
The Contractor confirms that it has been provided with sufficient written information regarding the
health and safety arrangements and procedures applicable to the Works to ensure compliance by it
and all employees, agents, Subcontractors or mandataries with the SHEQ Requirements while
providing the Works in terms of this contract. As such, the Contractor confirms that this contract and
the relevant Eskom Regulations referred to in this contract constitute written arrangements and
procedures between the Contractor and the Employer regarding health and safety for the purposes
of section 37(2) of the OHSA.
The Contractor agrees that the Employer is relieved of any and all of its responsibilities and liabilities
in terms of Section 37(1) of OHSA in respect of any acts or omissions of the Contractor, and the
Contractor’s employees, agents or Subcontractors, to the extent permitted by the OHSA.
The Contractor hereby indemnifies the Employer and holds the Employer harmless in respect of any
and all loss, costs, claims, demands, liabilities, damage, penalties or expense that may be made
against the Employer and/or suffered or incurred by the Employer (as the case may be) as a result
of, any failure of the Contractor, its employees, agents, Subcontractors and/or mandataries to
comply with their obligations in terms of this clause 18, and/or the failure of the Employer to procure
the compliance by the Contractor , its employees, agents, subcontractors and/or mandataries with
their responsibilities and/or obligations in terms of or arising from the OHSA.
The Contractor shall ensure that all statutory, legislative codes and regulations relating to South
African and Eskom’s Safety, Health and Environmental Policies and Procedures are adhered to
during the design, manufacture, construction and operation of the plant up to Take Over.
The Contractor shall be required to administer and control site activities in such a manner as to
achieve and maintain the safety of all persons on the Site, including employees, visitors and all sub-
contractors.
The Contractor shall make provision on all equipment, mechanical and electrical, for the placing of
locks for the purpose of isolation in accordance with procedures to be agreed with the Project
Manager.
The Contractor shall also comply with the Project Manager’s reasonable recommendations
regarding the temporary or permanent arrangement of ladders, gangways, working platforms,
fencing of openings, posting of warning signs and the wearing of appropriate safety equipment such
as safety harnesses, ear defenders etc. The wearing of safety glasses, safety helmets and safety
footwear at all times by all members of the workforce including management and visitors shall be
compulsory on the Site. These stipulations shall in no way release the Contractor from any
obligations under Occupational Health and Safety Legislation and this Contract.
A Site Safety Advisor will be appointed by the Employer and this person will act for the Employer in
an advisory capacity on all matters affecting the safety of all personnel engaged on the Site.
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1.1.7.1.1. Safety Surveillance Contract Requirements.
The Contractor shall have at least one full time experienced safety officer present on the
construction site at all times during construction. The safety officers shall be suitably qualified by
experience and training and shall be fully knowledgeable in South African Regulations and qualified
with an technical engineering qualification, and a minimum 5 years experience in heavy construction.
The safety officers brief shall be to advise the Contractor in matters of safety, to exercise general
supervision of the observance of safety requirements and to promote safe methods of work. The
Safety Officer Role shall be staffed by an adequate number of persons all qualified as stated above,
to effectively carry out the required safety duties in a timely and effective manner. CV’s for all safety
officers shall be submitted to the Employer for acceptance.
1.1.7.1.2. Safety and Health Plan
Before commencement of any activities on Site the Contractor shall prepare a detailed Safety and
Health Plan for the Project (to include all subcontractors activities), which shall be submitted to the
Project Manager for acceptance. Hard copies of the Safety and Health Plan revised in accordance
with the Employer’s comments shall be available on site before any work commences and all
subcontractors shall have signed that they have received and are familiar with the Safety and Health
Plan.
Detail included in the Safety and Health Plan shall include but not be limited to the following:
standard safe work practices,
identification of hazards including mitigation measures,
personnel protective equipment requirements,
plant inventory including certification,
inventory of employees including record of national safe training certification,
safety inductions (persons, workforce or visitors, shall not be permitted to enter the
construction site(s) unless they have been registered as having received the specific site
safety induction).
emergency evacuation procedures including muster points,
inventory of toolbox talks and attendees,
site safety incentive scheme details,
instructions to site security,
swipe card system (in place from day one (1)),
induction times,
induction training facility,
foreseeable risk assessment (for particular risks i.e. designation of confined spaces etc),
definitions of working-at-height requirements,
car parking external to site,
delineation/ongoing management of lay-down,
consultation arrangements weekly /monthly,
site progress meetings (health and safety No 1 on Agenda),
safety committee meetings (frequency agenda and persons attending),
safe working procedures,
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site perimeters,
speed limit,
waste management (designated skip area),
readily identifiable clean up crew for contractor interface management,
general site illumination and provision for change,
general site signage.
The Plan shall indicate the Contractor’s requirements for new contractors coming to site, Insurances,
site specific safety statements, training matrix (national accredited skills training certification )
proposed lay-down area etc.
The Project Safety and Health Plan must address commissioning activities and develop
commissioning safety rules and established plant tagging, locking systems to ensure safety and well
being of all on Site. This element will be synopsised and included in induction training for all
operatives coming to site.
1.1.7.1.3. Method Statements Risk Assessments (MSRA)
Each different work activity must have a MSRA. MSRAs will be produced by a competent member of
the Contractor’s team before being passed on to the Contractor’s safety office. Commencement of
any work activity shall not take place unless a MSRA including risk mitigation has been submitted to
the Project Manager, five working days in advance of any proposed commencement of the specific
activity. They must be site and task specific, clear and signed off by those undertaking the task and
each MSRA should be posted local to each activity.
1.1.7.1.4. Log of MSRAs
At contract signing a schedule of foreseeable risks must be tied into a specific list or log up front. A
monthly update of such a log must be emailed (supported by a facsimile) to the Project Manager.
1.1.7.1.5. Extent of Subcontracting
The approval of sub-vendors by the Contractor must be subject to the same Health and Safety
Criteria covered herein.
1.1.7.1.6. Safety File
The Contractor shall provide or procure information for and prepare a Safety File.
The Contractor shall provide a preliminary index of what is expected to go into the Safety File.
As a minimum the Safety File shall contain all of the following:
Design records relating to safety.
As-built drawings of the completed plant and site.
As-built process and instrumentation drawings.
Records of control and instrumentation system logic and settings.
Non-destructive test records.
Commissioning records for all plant proving fitness for purpose.
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Statutory certificates for all boilers, steam receivers, steam containers, air receivers, lifting
appliances and lifting gear.
Operating and maintenance instructions for all plant and systems.
An inventory of all hazardous substances on the plant along with all necessary safety
information for the substances involved.
Clearance certification where hazardous waste has been removed from the site.
The Employer’s site teams will review progress on a weekly basis starting at commencement of
work.
The completed Safety File, which is required to be handed over to the Project Manager on Take
Over, shall be provided in electronic form.
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1.2. Technical Requirements
1.2.1 Metrological Site Conditions
The equipment shall be designed as outdoor plant and the appropriate meteorological data is
included in Part 5.2 - Climatic Design Conditions.
1.2.2 Working Arrangements
1.2.2.1 Planning of Work
Work must be planned carefully and in particular in case of the fuel oil storage tanks expeditiously. It
would be required that the roof of the fuel tank be placed as soon as possible to reduce the risk of
wind damage to the tank during construction. The contractor shall consider the method of
construction such as installing the roof first tank and installing the strakes from the roof by jacking
the tank upwards. All precautions necessary to ensure safety of personnel and security of supplies
must be taken.
1.2.2.2 Protection of the shell during erection
The Contractor shall employ suitable methods for the protection of the shell during erection to be
agreed with the Project Manager. Full details of these methods shall be made available for the
Project Manager’s acceptance. The factors to be taken into account when determining the suitability
of the protection shall be:
Tank size
Construction methods
Location and degree of exposure to wind loads
Number and type of key plate equipment
Metrological data during all periods of erection
Note: The use of steel wire guys or cables may not necessarily be adequate and consideration
should be given to the use of temporary wind girders
1.2.3 Storage Tanks
1.2.3.1 Terminal Points
Low level nozzles at nozzle flanges and isolating valve.
High level or roof mounted pipe-work routed terminal points 1m above tank base with
nozzle flanges and isolating valve.
Supports for cable trays including to roof instruments
Foundations – Contractor to advise his requirements for the tank foundations in his
Contract documentation to the Employer.
1.2.3.2 Design Parameters
The diesel fuel oil and water storage system shall be supplied consisting of storage tanks as
described herein and shall be in accordance with Part 2.4 Schedule C (Tank sizing). All tank roofs
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should be self supporting in accordance with the applicable code of construction. The tanks shall be
designed to last a minimum of 20 years. The Contractor’s scope of supply of the storage tanks must
include the mechanical and process design.
The Contractor shall assume the following design features:
(a) Corrosion allowance of 1 mm
(b) The tanks must withstand all wind forces as specified in SANS 4302;2002 / ISO 4302;
“Cranes - Wind Load Assessment” 1981. A basic wind speed of 50 m/s (as measured at
10m above ground level) must be used in conjunction with the above wind code to derive
the wind forces imposed on the tanks. Note the average hourly wind speeds in m/s are
given in Sub Part 5.2 .1.2.3 (Wind) of Part 5 (Site Information Storage Tank Specification).
Every reasonable protective device for the safety of operating personnel shall be incorporated. All
current safety regulations and requirements for such installations in force in Republic of South Africa
shall be complied with.
A contractor accepted by the Project Manager shall carry out exact calibration of the tanks.
1.2.4 Details of Tanks and Accessories Lots 1 to 2
4.1.1.1 General
The following table shall be used as a guide when sizing the fuel oil plant nozzles.
Limiting velocities
Diameters
NB≤50
80≤NB≤250
NB≥300
Transferring between tanks and unloading road tankers
1.0 m/s
1.0 m/s
1.0 m/s
Pump suction
0.6 m/s
1.0 m/s
1.8 m/s
In Plant
2.0 m/s
3.0 m/s
4.5 m/s
Main link
1.0 m/s
2.0 m/s
2.1 m/s
4.1.1.2 Operational philosophy of Diesel Fuel Oil tanks
Diesel Fuel tanks are required for Ankerlig Power Station and they will be arranged as shown in
P&ID’s 0.87/1 and 0.88/1 respectively included in Appendix E.
On Atlantis there will be two tanks whereby the diesel fuel oil can be received from road tanker by
either of two tanks. The normal operation is that both tanks will be nominated as the dirty receiving
tanks and will therefore not require a floating suction. Diesel fuel off loading from the road tankers to
the new tanks will be linked to the existing off loading bays in Ankerlig 2. Diesel fuel shall be
transferred from the new storage tanks to existing Tank 3 and Tank 2. If required this will allow for
one tank at a time to be taken out of service for maintenance. New storage tank selection for
offloading shall be done with remote control valve selection. Tank design shall include ports and
isolating valves for offline filtration system.
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1.2.4.1 General
Part 2.4 Schedule G contains the full details of the material specifications provided by the contractor.
The shell plate material shall also meet the code requirements including toughness, impact test and
heat treatment.
All shell vertical and horizontal joints shall be butt-welded with full penetration.
Wind girders must be of the external type (if required).
Roof plates to be additionally seal welded internally.
The Contractor is responsible for the design, manufacture, installation and commissioning of floating
suctions in the distillate fuel oil tanks including all associated pipe work and ancillaries.
1.2.4.2 Design Standards
All work shall be in accordance with the most recent edition of the relevant ASME, API, ASTM,
British Standard Specification or equivalent. The distillate tanks shall be of steel circular welded
construction and shall be fully compliant with:
American Petroleum Institute (API), API 650: Welded Steel Tanks for Oil Storage
API Recommended Practice 2350: Overfill Protection for Storage Tanks in Petroleum
Facilities
API 2000: Venting Atmospheric and Low Pressure Storage Tanks
All dimensions and quantities shall be expressed in SI units.
1.2.4.3 Tank Drainage
A draw-off sump shall be located at the centre of each tank and the tank floor shall be adequately
sloped to the sump to ensure complete drainage of water. The drainage slope shall not be less than
one in sixty.
1.2.4.4 Nozzle Details and Fittings
All nozzle flanges and blanks are to be raised faced ANSI Class 150. The Contractor shall provide
blanks and gaskets for all nozzles and fittings. All gaskets shall be of the spiral wound type. These
may be used during the hydro-test and are to be kept as spares by the Employer on completion of
the hydro-test. Additional gaskets shall be provided for those used during the hydro-test. An overflow
pipe shall be piped externally to 1m above the ground level. Precise nozzle orientations will be
agreed with the Project Manager. Confirmation of the precise orientation of the nozzles will be
provided by the Project Manager two months after contract award.
For tendering purposes a nozzle schedule has been included but tank nozzle orientation will be
different for each individual tank.
Nozzle allowable loadings shall be provided by the Contractor to the Employer within one month of
contract award.
1.2.4.5 Materials
All materials shall be new, and of a quality most suited to the proposed application.
1.2.4.6 Instrumentation
For each tank the Contractor shall provide the level gauge and temperature gauge at eye level
including isolation valves.
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All instrumentation shall be fit for use and suitable for the hazardous zone classification of the tanks.
The Contractor shall include all supports for cable trays including to roof instruments.
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Lot 1: Two (2) off 21000 m³ Distillate Fuel Tank (Welded) for Atlantis Site.
Tank requirements are as follows:
Tanks to have usable capacity of 21000m3
Water draw-off sumps with necessary pipe connections to outside shell c/w external valves
Three earthing bosses spaced at 120° to be located at low level
Asbestos gaskets are not allowed
One 750 mm external spiral stairway with intermediate landing(s) and handrail on tank and
chain barriers at top and base
One external ladder with intermediate landing(s) and safety cage on tank
Transition landing and staircase from base of spiral staircase to ground level
Gangways across tank roof to the various roof connections
One handrail around periphery of tank roof. Handrails to be fitted with toe plates
Sign at top of tank indicating safe load for personnel access
Membrane system under tank floor
Name Plate incorporating description, KKS coding, contents and code of construction
Permanent wind girders where required
Mechanical tank level indicators (Varec)
All handrails to be of angle iron design with flat bar mid and toe plates
Fill lines and main return lines to tanks to be fitted with diffusers and to conform to NFPA
30 guidelines with regards to anti-static electricity
All tank internals to be removable through local manways
Nozzles shall be provided as outlined below:
No. Flowrate
kg/s
Size NB Elevation Description
M1 - 600 1000 Shell manway c/w cover
M2 - 900 1000 Shell manway c/w cover & davit
M3 - 600 Roof Roof manway c/w cover
M4 - 600 Roof Roof manway c/w cover
N1 168 500 500 Fuel supply to storage Tank 2 and 3
N2 55 300 425 Fill line from unloading skid (with internal piping
and diffuser
N3 66 300 425 Clean oil return line with diffuser from offline
filtration
N4 150 400 16300 Main return line with vacuum breaker with
diffuser
N5 66 300 425 Feed line offline filtration system
N6 - 25 225 Access port for level transmitter
N7 - 50 1500 Access port for temperature gauge
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No. Flowrate
kg/s
Size NB Elevation Description
N8 - 50 2000 Access port for temperature transmitter
N9 - 100 150 Sump drain at low level
N10 - 250 Roof Tank breather on roof
N11 - 250 Roof Tank breather on roof
N12 - 100 Roof Dip hatch with cap and chain on roof
N13 - 100 Roof Dip hatch with cap and chain on roof
N14 - 100 Roof Access port for electronic level transmitter
N15 - 300 425 Spare fill line at ground level
N16 400 Balance Line
N17 - 300 425 Spare fill line at ground level with diffuser
N18 - 50 1500 Spare nozzle at low level
N19 - 25 Roof Access port for high-high level switch
N20 - 40 Roof Access port for local visual level indicator
N21 - 100 Roof Access port for radar level transducer
N22 - 100 Roof Access port for radar level transducer
N23 26 250 1500 Fuel transfer nozzle
N24 26 250 1500 Fuel transfer nozzle at low level with diffuser
1.2.5 Details of Tank and Accessories Lot 3
Lot 3: One (1) No. 2000 m³ fire water storage tank Atlantis Site
Tank requirements are as follows:
The firewater tank is to be of bolted Braithwaite design
Tank partitioned into two compartments each with usable volume of 1000m3
Each compartment to be fitted with all required nozzles including raw water inlet, outlet to
fire system and outlet to water treatment system
Water draw-off sump with necessary pipe connections to outside shell c/w external valves
Three earthing bosses located at low level
Asbestos gaskets are not allowed
Each compartment to have one internal ladder from base to roof manway
One external ladder per compartment with safety cage on tank. Ladders shall have
intermediate platforms where required by BS EN ISO 14122.
Gangways across tank roof to the various roof connections
Manways to have padlock facility
A handrail around the periphery of the tank roof
All handrails to be of angle iron design with flat bar mid and toe plates
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Sign at top of tank indicating safe load for personnel access
Name Plate incorporating description, KKS coding, contents and code of construction
One mechanical local visual level indicator per compartment
Nozzles shall be provided as outlined below:
No. Size NB Description
M1 600 Shell man-way on roof - Compartment 1
M2 600 Shell man-way on roof - Compartment 2
M3 600 Shell man-way on roof - Compartment 1
M4 600 Shell man-way on roof - Compartment 2
N1 150 Fire recirculation at high level – Compartment 1
N2 150 Fire recirculation at high level – Compartment 2
N3 300 Water supply to fire-fighting at low level – Compartment 1
N4 300 Water supply to fire-fighting at low level – Compartment 2
N5 150 Spare nozzle at high level – Compartment 1
N6 150 Spare nozzle at high level – Compartment 2
N7 250 Return line from fire-fighting at high level – Compartment 1
N8 250 Return line from fire-fighting at high level – Compartment 2
N9 150 Inlet from mains water at high level – Compartment 1
N10 150 Inlet from mains water at high level – Compartment 2
N11 150 Spare fill line at high level - Compartment 1
N12 150 Spare fill line at high level – Compartment 2
N13 100 Access port for level gauge at high level – Compartment 1
N14 100 Access port for level gauge at high level – Compartment 2
N15 100 Access port for level gauge at low level – Compartment 1
N16 100 Access port for level gauge at low level – Compartment 2
N17 100 Drain at low level – Compartment 1
N18 100 Drain at low level – Compartment 2
N19 100 Drain at low level – Compartment 1
N20 100 Drain at low level – Compartment 2
N21 100 Drain at low level – Compartment 1
N22 100 Drain at low level – Compartment 2
N23 150 Spare at low level – Compartment 1
N24 150 Spare at low level – Compartment 2
N25 250 Spare at low level – Compartment 1
N26 250 Spare at low level – Compartment 2
N27 200 Water test nozzle on roof – Compartment 1
N28 200 Water test nozzle on roof – Compartment 2
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No. Size NB Description
N29 250 Tank breather on roof – Compartment 1
N30 250 Tank breather on roof – Compartment 2
N31 250 Tank breather on roof – Compartment 1
N32 250 Tank breather on roof – Compartment 2
N33 100 Dip hatch with cap and chain on roof – Compartment 1
N34 100 Dip hatch with cap and chain on roof – Compartment 2
N35 100 Dip hatch with cap and chain on roof – Compartment 1
N36 100 Dip hatch with cap and chain on roof – Compartment 2
N37 100 Access port for electronic level measurement – Compartment 1
N38 100 Access port for electronic level measurement – Compartment 2
N39 200 Overflow at high-high level – Compartment 1
N40 200 Overflow at high-high level – Compartment 2
N41 50 Water supply to water treatment skid (located to reserve 800m3 for fire
water) – Compartment 1
N42 50 Water supply to water treatment skid (located to reserve 800m3 for fire
water) – Compartment 2
1.2.6 Corrosion Protection
The tank, including the underside of the tank floor-plates, should be fully protected against
deterioration from corrosion. For distillate fuel and lubrication oil the interior of the tanks shall have a
protective coating system applied to the tank bases and the tank shells. For the fuel oil tanks the
painting systems applied should be chemically resistant to distillate fuel oil. Similarly the painting
system used for the lubrication oil tanks should be chemically resistant to the lubrication oil utilised.
For water storage a suitable protective coating system shall be applied to the entire interior and
exterior of the tank shell and roof. Paint shall be applied by airless spray. All handrails, stairs,
ladders, support structures and catwalks shall be hot dipped galvanised.
1.2.6.1 Exterior Paint Protection System
The paint protection system proposed for application to carbon steel parts on the external shell and
under-floor of the tank floor plates shall conform to EN ISO 12944 to C5-M or equivalent. The
Contractor shall detail the proposed painting system and standards in Schedule H (Painting
Specification) of Sub Part 2.4 (Data Schedules) of Part 2 (Tender Returnables). The colour of the
paint for the exterior shall be white as agreed by the Project Manager.
1.2.6.2 Underside of Tank Floor-plates Paint Protection System
The Underside of Tank Floor-plates shall be painted with an appropriate paint protection system in
sufficient time to allow paint to dry freely before placing in position for commencement of welding.
The Contractor should detail the proposed painting system and standards in section Schedule H
(Painting Specification) of Sub Part 2.4 (Data Schedules) of Part 2 (Tender Returnables). The
Contractor should also detail the potential lifetime of the paint protection system.
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1.2.6.3 Interior Paint Protection System
The internal of the tank shell shall be painted with an appropriate paint protection system. The tank
shall be painted once the hydro-test has been completed. The Contractor should detail the proposed
painting system and standards in section Schedule H (Painting Specification) of Sub Part 2.4 (Data
Schedules) of Part 2 (Tender Returnables).
1.2.7 Cleanliness, Preparation, Painting, Finishing and Repairs of Painted
Surfaces
1.2.7.1 Cleanliness of the System: Treatment of Internal Surfaces
Every reasonable precaution shall be taken to ensure the cleanliness of the system at pre-
manufacture stages and during manufacture, assembly, erection and commissioning of the tank.
The Contractor shall comply with the conditions stipulated in this clause over and above the normal
procedures adopted for ensuring cleanliness. The Contractor and his sub-Contractors shall comply
with all reasonable requirements of the Project Manager in maintaining the highest standards of
workmanship and cleanliness during erection.
1.2.7.2 Protection, Painting, Finishing and Packing
The tanks shall be suitably protected at all stages of construction. Subsequent to final manufacture
phase, all tank components shall be protected against deterioration due to corrosion. This
requirement covers storage at the Contractor’s works, packing for transport, transport arrangements
and storage on Site.
1.2.7.3 Surface Preparation and Conditions for Painting
All surfaces shall be dry and free of dust, salts, greases and other contaminants immediately before
coating.
The metal surface temperature as specified by the paint manufacturer shall be adhered to.
1.2.7.4 External Tank Painting and Under-floor Plates
Shot or grit blasting to ISO 8501-1:1988 SA 2.5 shall clean the surface. Detritus shall be removed
from the surface by vacuum cleaning. The blast profile achieved shall be between 50 and 100
microns. Priming paint shall be applied within four hours of surface preparation otherwise the
surfaces shall be re-prepared.
1.2.7.5 Internal Tank Painting
Shot or grit blasting to ISO 8501-1:1988 SA 3 shall clean the surface. Detritus shall be removed
from the surface by vacuum cleaning. The blast profile achieved shall be between 50 and 100
microns. Priming paint shall be applied within four hours of surface preparation otherwise the
surfaces shall be re-prepared.
1.2.7.6 Priming Coats – Shop Priming Coat
Where the Contractor wishes to use pre-primed steel plate and sections for fabricating the plant, the
shop-priming coat shall conform to the following.
A priming coat of a weldable two component low build epoxy resin based zinc phosphate paint shall
be applied to a dry film thickness (DFT) of 15 to 20 microns. (see API 650 section 5.2.1.9)
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1.2.7.7 Post Welding Surface Treatment and Priming
Immediately after completion of welding, the areas of paintwork which have been affected by the
welding process shall be shot blasted and primed to conform to Sub Part 1.2.7.6 (Priming Coats –
Shop Priming Coat) first priming coat.
1.2.7.8 Repair of Damaged Paint-work
All paintwork, which may be damaged during transport, handling, storage or erection, shall be
repaired on Site as follows:
Priming Coat Damaged - External and Under-floor Plates
Where the priming coat has been damaged, the damaged area shall be power wire brushed to clean
metal equivalent to ISO 8501-1:1988 - St 3. This shall be followed by vacuum cleaning to remove
detritus and the full paint shall be re-applied to the affected area to a total DFT of 350 microns,
minimum.
Priming Coat Damaged - Internal Tank Plates
Where the priming coat has been damaged, the damaged area shall be shot or grit blasted to clean
metal equivalent to ISO 8501-1:1988 – Sa 2.5. This shall be followed by vacuum cleaning to remove
detritus and the full paint shall be re-applied to the affected area to a total DFT of 350 microns,
minimum.
Potential Life of Restored Paintwork
All remedial action shall restore the damaged coating to the same potential life as that of the
undamaged areas.
1.2.7.9 Control of Paint Thickness
For consistent and economical application of paint, the paint film thickness shall be controlled during
application by monitoring the Wet Film Thickness (WFT). A relationship shall be established
between WFT and DFT beforehand by preparing and painting a suitable test plate, before
preparation of metal surfaces for painting occurs.
Dry Film Thickness
Method of determining the final DFT shall be to take readings over any square metre of the painted
area, the average of these readings shall equal or exceed the nominal DFT and in no case shall any
reading be less than 75% of nominal DFT. The same method shall be applied to determining WFT.
1.2.7.10 Areas for Special Attention
Special attention shall be given to painting of:
Mating surfaces of connections
Contact surfaces with concrete
Interior Base of Tank
Welds and areas adjacent to welds
Strip coats should be applied if deemed necessary
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1.2.7.11 Compatibility of Paints
All paints shall be by the same manufacturer and shall be compatible with one another.
1.2.8 Pipework
All pipe-work for fuel storage shall be API 5L grade B schedule 40.
All pipe-work for water storage shall be to galvanised carbon steel (ASTM A106 grade B or API 5L
B).
1.2.9 Tank Labelling
The Contractor shall provide labelling on the tank stating the tank number and the type of (liquid) fuel
it contains. This should be clearly seen from the outside of the bund.
1.2.10 Civil Requirements
1.2.10.1 Materials for Civil Works
The Contractor shall supply all embedded anchor bolts, jacking posts, sleeves, anchors and other
miscellaneous embedded parts necessary for the installation of the tanks and required to be
incorporated in the civil works, including, if necessary, setting templates required for anchor bolt
placement. A civil contractor will incorporate all such items into the structures under a separate
contract. Materials shall be supplied and proper and sufficient drawings and templates shall be
provided in sufficient time to ensure the items are incorporated in the civil works.
1.2.10.2 Information for Civil Works
Information required for the timely planning, design and construction of the civil works shall be
provided by the Contractor as required. The Contractor provides all the necessary information in the
detail required and at the appropriate time. The Contractor specifies any specific requirements for
tank foundations taking into consideration local conditions.
Information shall be provided at three levels of detail namely outline, basic and definitive.
Outline information shall include the main dimensions and arrangement planning of structures
together with preliminary plant loads.
Basic information shall be at such level of detail as to allow the execution of calculations to within an
accuracy of +10% and the preparation of draft drawings. Basic information shall be provided within 1
week of contract award.
Definitive information shall provide final definitive loading information and allow the preparation of
detailed execution and construction drawings for the civil works. Definitive information shall be
provided within 4 weeks of contract award.
The information to be provided shall include the following:
Design Calculations
Arrangement drawing indicating detailed tank geometry
Loadings imposed by tank and equipment
Criteria for settlement of tank foundations
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Details of all plinths, openings, box-outs holding down arrangements, grouting etc.,
required for tank
1.2.11 Final Information to be Supplied before Contract Completion
A technical file for the Storage Tanks shall be submitted prior to the Completion Date.
A Table of Contents for the technical file shall be submitted to the Project Manager for comment and
review prior to the compilation of the technical file.
Four hard copies of all documentation shall be submitted before the Contract is deemed to be
complete. In addition to the hard copies a soft copy shall also be submitted, with all files in their
native application.
The Contractor shall supply complete descriptive details and as built drawings of the tanks, giving
full particulars of the materials used.
The Contractor shall submit detailed loading values of the tank giving the maximum loads. Any point
loads shall be identified and their location detailed on a drawing.
The Contractor shall submit a detailed record of material certificates, the plate preparation, welding
and NDE records, and hydro-test results.
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1.3. APPENDICES
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1.3.1 APPENDIX A – CODES AND STANDARDS
API 2000, 5th Edition, Apr. 1998 Venting Atmospheric and Low-Pressure Storage Tanks
API Recommended Practice 2350, 3rd
Edition, Jan. 2005
Overfill Protection for Storage Tanks in Petroleum Facilities
API Standard 650 10th Edition, Nov. 1998 Welded Steel Tanks for Oil Storage
BS2654:1989 British Standard Specification for Manufacture of vertical
steel welded non-refrigerated storage tanks with butt-
welded shells for the petroleum industry
EN14015: 2004 Specification for the design and manufacture of site built,
vertical, cylindrical, flat-bottomed, above ground, welded,
steel tanks for the storage of liquids at ambient
temperature and above
BS EN ISO 14122 (Part 1 to 4 inclusive) Safety of machinery – Permanent means of access to
machinery
ESKAMAAD1 Rev 2 Storage and Handling of Flammable and Combustible
Liquids
GGG 0450 Guideline to Acceptance of Contractors Drawings
GGR 0992 Eskom Plant Safety Regulations
GGS 0445 Drawing numbering system
GGSS 0317 Specification for Storage Tanks
KSA-106 Requirements For Protective Coatings For Use At Koeberg
Nuclear Power Station
OPS 0002 Eskom Documentation Standard
SABS 1109 ISO pipe threads for pipes and fittings where pressure –
tight joints are made on the threads.
SABS 1123 Steel pipe flanges
SABS 719 Electric welded low carbon steel pipes for aqueous fluids
(ordinary Duties)
SABS 763 Hot-dip (galvanized) zinc coatings
SABS 974-1 Rubber joint rings (non-cellular) for use in water, sewer and
drainage systems
SANS 10089-1:2003 Part 1 Storage and distribution of petroleum products in above-
ground bulk installations
SANS 10108 The classification of hazardous locations and selection of
electric apparatus for use in such locations
SANS 10140-3 Identification Colour Markings
SANS 1091 National colours for paint
SANS 9000 to 9004 Quality Management systems and standards
1.3.2
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1.3.3 APPENDIX B – ABBREVIATION LIST
BOP Balance of Plant
C&I Control & Instrumentation
DCIS Distributed Control and Information System
EN European Norm
ESV Emergency Stop Valve
FAT Factory Acceptance Test
GRP Glass- Reinforced Polyester
GT Gas Turbine
HMI Human Machine Interface
HV High Voltage
LCS Local Control Push Button Station
MCB Miniature Circuit Breaker’s
MCC Motor Control Centre
NB Nominal Bore
NEC New Engineering Contract
NDT Non-Destructive Testing
NERSA National Energy Regulator of South Africa
NFPA National Fire Protection Association
OCGT Open Cycle Gas Turbine
OEM Original Equipment Manufacturer
OHSA Occupational Health and Safety Authority
O&M Operation and maintenance
PCC Power Control Centre
PLC Programme Logic Control
PIP Project Implementation Plan
PPE Personal Protective Equipment
PSQP Project Specific Quality Plan
P&ID Piping and Instrumentation Diagram
QAM Quality Assurance Manual
SANS South African National Standard
SAT Site Acceptance Test
SHEQ Safety, Health, Environment & Quality
SI International System
SQAP Site Quality Assurance Programme
SWL Safe Working Loads
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WPS Welding Procedure Specification
WPAR Weld Procedure Approval Records
WQAP Works (Manufacturer’s Facility) Quality Assurance Programme
WQR Welder Qualification Records
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1.3.4 APPENDIX C – SAFETY, HEALTH AND ENVIRONMENTAL
Appendix C - Section 1
Ankerlig Safety, Health & Environmental Specification
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Appendix C - Section 2
Environmental Report
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1.3.5 APPENDIX D - CORROSION PROTECTION
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1.3.6 APPENDIX E - DRAWINGS
The following Drawings are included in the enquiry:
Atlantis Ankerlig 2 Site
0.88/1 Station Layout
0.88/4 P&ID Demineralised Water System
0.88/8 P&ID Fire Water System
0.88/28 Fire water storage tank
RSA805-UC07-UZ-110001 Siemens Layout Showing Terminal Points