reference rev title specification for an cp … - exothermic... · reference rev title...

REFERENCE REV

TITLE SPECIFICATION FOR AN

EXOTHERMIC WELDING SYSTEM

CP_TSSPEC_055 2

DATE: April 2013

PAGE: 1 OF 15

TABLE OF CONTENTS

Page

FOREWORD ....................................................................................................................................... 2

INTRODUCTION ................................................................................................................................. 3

1 SCOPE ........................................................................................................................................... 3

2 NORMATIVE REFERENCES ........................................................................................................ 3

3 DEFINITIONS AND ABBREVIATIONS ......................................................................................... 3

4 REQUIREMENTS .......................................................................................................................... 3

4.1 General ................................................................................................................................... 3

4.2 Tool Kits.................................................................................................................................. 3

4.3 Moulds .................................................................................................................................... 4

4.4 Consumables ......................................................................................................................... 4

5 TESTS ............................................................................................................................................ 5

6 MARKING AND PACKAGING ....................................................................................................... 5

7 DOCUMENTATION ....................................................................................................................... 5

8 TRAINING ...................................................................................................................................... 5

9 QUALITY ASSURANCE ................................................................................................................ 5

10 ENVIRONMENTAL MANAGEMENT ............................................................................................. 5

Annexure A - Bibliography ............................................................................................................... 6

Annexure B - Revision information ................................................................................................. 7

Annexure C - Technical schedules A and B for Tool Kits ............................................................. 8

Technical schedules A and B for Moulds ..................................................................................... 10

Technical schedules A and B for Consumables .......................................................................... 12

Annexure D – Stock Items .............................................................................................................. 14

SPECIFICATION FOR AN EXOTHERMIC

WELDING SYSTEM

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FOREWORD

Recommendations for corrections, additions or deletions should be addressed to the: Technology Services General Manager

City Power Johannesburg (Pty) Ltd

P O Box 38766

Booysens

2016


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INTRODUCTION

Earthing of power systems is an essential and integral part of City Power’s electrical infrastructure. Failure of any part of the earthing system results in serious and potentially catastrophic consequences. It has been determined that an exothermic welding system is the most reliable method of bonding and connecting earthing conductors. It is therefore important to ensure that all earthing components comply with the required specifications and are of acceptable quality. As this is difficult to manage within the present City Power business structures it has been decided that SANS support structures will be relied upon to manage compliance to specification as well as quality. The implication to suppliers is that City Power will only purchase an exothermic welding system that complies with the relevant IEEE standard.

1 SCOPE

This specification covers City Power’s requirements for an exothermic welding system in accordance with IEEE 80.

2 NORMATIVE REFERENCES

The following documents contain provisions that, through reference in the text, constitute requirements of this specification. At the time of publication, the editions indicated were valid. All standards and specifications are subject to revision, and parties to agreements based on this specification are encouraged to investigate the possibility of applying the most recent editions of the documents listed below.

CP_TSSPEC_056, Specification for earth rods, couplers

IEEE 80: Guide for safety in AC substation grounding

SCSASACH1: ESKOM Standard for utilizing copper clad steel as earth tails for distribution substations in high copper theft areas

3 DEFINITIONS AND ABBREVIATIONS

The definitions and abbreviations in the normative reference shall apply to this specification.

4 REQUIREMENTS

4.1 General

4.1.1 The exothermic welding system shall be galvanically compatible with copper-clad steel conductors and earth rods complying with CP_TSSPEC_056.

4.1.2 The components shall be designed for use in a system that may be either solidly or resistively earthed, and subject to frequent high intensity lightning storms.

4.1.3 The exothermic welding system shall be easy to use.

4.1.4 The exothermic welding system shall be as described in IEEE 80.

4.2 Tool Kits

4.2.1 The tool kits shall contain all the items necessary to correctly and safely perform the exothermic welding process.


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4.2.2 Each tool kit shall contain the following items:

4.2.2.1 At least two sets of mould handles or clamps;

4.2.2.2 Mould cleaning equipment (scrapers, wire and bristle brushes);

4.2.2.3 Safety equipment (gloves, apron and goggles or face shield);

4.2.2.4 At least three driving caps (for driving earth rods described in CP_TSSPEC_056);

4.2.2.5 Sealing putty or similar for worn moulds;

4.2.2.6 A flint gun for powder ignition; and

4.2.2.7 Spare flints for the flint gun.

4.2.3 The items listed above shall be supplied in a sturdy metal or plastic toolbox.

4.2.4 Extra sets of mould handles or clamps shall be supplied on request.

4.3 Moulds

4.3.1 The moulds shall be capable of being used for a minimum of 200 welds and shall be constructed of graphite or similar material.

4.3.2 The moulds shall be supplied in the following configurations (all references to earth rods shall mean 14,2 mm i.e. M16 earth rods complying with CP_TSSPEC_056):

4.3.2.1 EES – M16 earth rod to M16 earth rod in a side by side configuration (parallel);

4.3.2.2 E7S – 70 mm2 stranded copper conductor to M16 earth rod in a side by side

configuration (parallel);

4.3.2.3 E7T – 70 mm2 stranded copper conductor to M16 earth rod in a T

configuration; and

4.3.2.4 S-P – M12 stud to steel plate configuration. The steel plate will be vertical, and may be either flat or curved (e.g. a steel pole or the side of a transformer tank).

4.4 Consumables

4.4.1 Weld metal and ignition powder shall be supplied in suitable containers for use with moulds having the configurations detailed in clause 4.3.2 of this specification.

4.4.2 Each container shall contain sufficient weld metal and ignition powder for one weld. The container shall be marked with its capacity in order to ensure that the correct amount of weld metal is used with a particular mould.

Note: A copper M12 stud is required to be provided with each weld metal for item 8 (SAP code 508).

4.4.3 Each container shall also be supplied with a suitable metal retaining disc, the purpose of which is to prevent the weld metal from falling into the mould before ignition.

4.4.4 In order to restore corrosion protection that may have been removed prior to the welding process, zinc spray in an aerosol form is required. Aerosol spray is preferred to


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paint because of the ease of application and the lack of cleaning up required in comparison to traditional paint and brush methods.

5 TESTS

The manufacturer shall submit detailed test reports that it may be in possession of. In particular, Eskom test reports relating to the product offered will result in that product being viewed in a favourable light.

6 MARKING AND PACKAGING

6.1 All equipment offered shall bear the name of the manufacturer, as well as a manufacturer’s reference number.

6.2 In addition, containers of weld metal shall be marked with the appropriate capacity and mould reference number of the manufacturer.

6.3 Tool kits shall be delivered individually, but all other items and consumables shall be delivered in suitable cardboard boxes.

7 DOCUMENTATION

7.1 Detailed test reports (if available) confirming compliance with IEEE 80 shall be provided.

7.2 In addition to the documentation required above, full technical information relating to the performance of the exothermic welding system shall be supplied.

8 TRAINING

8.1 The following training course shall be offered for City Power’s staff; correct procedure for performing welds using the exothermic welding system, with particular emphasis on safety and performance.

8.2 The associated costs for the certified training course in 8.1 shall be given per person and shall be fixed for the period of the contract.

9 QUALITY ASSURANCE

A quality management plan shall be set up in order to assure the proper quality management of exothermic welding system during design, development, production and installation. Guidance on the requirements for a quality management plan may be found in the ISO 9001. The details shall be subject to agreement between City Power and the Supplier.

10 ENVIRONMENTAL MANAGEMENT

An environmental management plan shall be set up in order to assure the proper environmental management of exothermic welding system throughout its entire life cycle (i.e. during design, development, production, installation, operation, decommissioning and disposal phases). Guidance on the requirements for an environmental management system may be found in ISO 14001 standards. The details shall be subject to agreement between City Power and the Supplier. This is to ensure that the asset created conforms to environmental standards and City Power Policy.


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Annexure A - Bibliography

SCSASACH1: 2001, ESKOM STANDARD FOR UTILIZING COPPER CLAD STEEL AS EARTH TAILS FOR DISTRIBUTION SUBSTATIONS IN HIGH COPPER THEFT AREAS.


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Annexure B - Revision information

DATE REV. NO. NOTES

Mar 2003 0 First issue

June 2006 1 General editing

Change of copper stud from M16 to M12.

Update of Annex D.

November 2012 2 Logo editing

Content updating

Quality management updated

Environmental management included.

Technical schedules updated


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Annexure C - Technical schedules A and B for Tool Kits

Schedule A: Purchaser's specific requirements

Schedule B: Guarantees and technical particulars of equipment offered

Item Sub-clause of

CP_TSSPEC_055

Description Schedule A Schedule B

1 4.1 Name of manufacturer XXXX

2 4.2 Place of manufacture XXXX

3 4.2 Manufacturer’s identification reference XXXX

4 4.3 & 4.4 Specification to which tool kit complies XXXX

5 4.2.2 Does the toolkit contain all the items required in clause 4.2.2?

Yes/No Yes

6 6 Marking as per clause 6 Yes/No Yes

7 6 Packaging as per clause 6 Yes/No Yes

8 7 Is all the information requested in clause 7 supplied?

Yes/No Yes

9 9 Quality management accreditation Yes/No Yes

10 10 Environmental management accreditation

Yes/No Yes

Note: Ticks, Cross [√, X], Astrick [*], Word [Noted] or TBA [“To Be Advice”] will not be accepted.

Tender Number: _________________________________________________________________

Tenderer’s Authorised Signatory: _________________________________ __________________

Name in block letters Signature

Full name of company: _____________________________________________________________


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Technical schedules A and B

Deviation schedule

Any deviations offered to this specification shall be listed below with reasons for deviation.

In addition, evidence shall be provided that the proposed deviation will at least be more cost-

effective than that specified by City Power.

Item Sub-clause of

CP_TSSPEC_055

Proposed deviation

Tender Number: _________________________________________________________________





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Technical schedules A and B for Moulds



Item Sub-clause of

CP_TSSPEC_055





4 4.3 & 4.4 Specification to which moulds comply XXXX

5 4.3.2 Are the moulds supplied in the configurations required in clause 4.3.2?

Yes/No Yes

6 4.3.1 Material of mould Graphite or similar




Yes/No Yes



Yes/No Yes


Tender Number: _________________________________________________________________





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Deviation schedule




Item Sub-clause of

CP_TSSPEC_055

Proposed deviation

Tender Number: _________________________________________________________________





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Technical schedules A and B for Consumables



Item Sub-clause of

CP_TSSPEC_055





4 4.3 & 4.4 Specification to which consumables comply

XXXX

5 4.6 Are the weld metal containers supplied with a retaining disc?

Yes/No Yes

6 4.6 Are the weld metal containers marked with the capacity of the contents and the mould reference number?

Yes/No Yes

7 4.7 Is the zinc spray supplied in an aerosol form?

Yes/No Yes

8 N/A Is the spray nozzle non-clogging? Yes/No Yes

9 4.4.2 Is a copper M12 stud provided? Yes/No Yes

10 4.2.4 Is a handle suitable for all moulds provided?

Yes/No Yes




Yes/No Yes



Yes/No Yes


Tender Number: _________________________________________________________________





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Deviation schedule




Item Sub-clause of

CP_TSSPEC_055

Proposed deviation

Tender Number: _________________________________________________________________





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Annexure D – Stock Items

Material Group: NET-ACCS

Item SAP No. SAP Short Description SAP Long Description

1 498 MOULD REF EES MOULD, GRAPHITE, REFERENCE EES, FOR USE WITH EXOTHERMIC WELDING SYSTEM, M16 EARTH ROD TO M16 EARTH ROD IN A SIDE BY SIDE (PARALLEL) CONFIGURATION. ITEM SPECIFICATION NO. CP_TSSPEC_055.

2 499 MOULD REF E7S MOULD, GRAPHITE, REFERENCE E7S, FOR USE WITH EXOTHERMIC WELDING SYSTEM, 70 MM2 COPPER TO M16 EARTH ROD IN A SIDE BY SIDE (PARALLEL) CONFIGURATION. ITEM SPECIFICATION NO. CP_TSSPEC_055.

3 500 MOULD REF E7T MOULD, GRAPHITE, REFERENCE E7T, FOR USE WITH EXOTHERMIC WELDING SYSTEM, 70 MM2 COPPER TO M16 EARTH ROD IN A T CONFIGURATION. ITEM SPECIFICATION NO. CP_TSSPEC_055.

4 501 MOULD REF S-P MOULD, GRAPHITE, REFERENCE S-P, FOR USE WITH EXOTHERMIC WELDING SYSTEM, M12 COPPER STUD TO PLATE CONFIGURATION. ITEM SPECIFICATION NO. CP_TSSPEC_055.

5 505 WELD METAL REF EES WELD METAL SUITABLE FOR USE WITH MOULD REFERENCE EES (EXOWELD REF WM200). ITEM SPECIFICATION NO. CP_TSSPEC_055.

6 506 WELD METAL REF E7S WELD METAL SUITABLE FOR USE WITH MOULD REFERENCE E7S. ITEM SPECIFICATION NO. CP_TSSPEC_055.

7 507 WELD METAL REF E7T WELD METAL SUITABLE FOR USE WITH MOULD REFERENCE E7T. ITEM SPECIFICATION NO. CP_TSSPEC_055.

8 508 WELD METAL REF S-P WELD METAL SUITABLE FOR USE WITH MOULD REFERENCE S-P, COMPLETE WITH M12 COPPER STUD. ITEM SPECIFICATION NO. CP_TSSPEC_055.

9 502 MOULD HANDLE MOULD HANDLE, SUITABLE FOR USE WITH ANY MOULD USED FOR EXOTHERMIC WELDING SYSTEM. ITEM SPECIFICATION NO. CP_TSSPEC_055.

10 509 ZINC SPRAY SPRAY, ZINC, FOR USE IN CONJUNCTION WITH EXOTHERMIC WELDING SYSTEM FOR THE PREVENTION OF CORROSION. ITEM SPECIFICATION NO. CP_TSSPEC_055.

11 504 EXOTHERMIC TOOL KIT TOOL KIT FOR EXOTHERMIC WELDING, COMPLETE WITH TOOL BOX AND ACCESSORIES. ITEM SPECIFICATION NO. CP_TSSPEC_055.

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