Document No.:H500206-1-413-E-SP-0006-01- JV Contract

Transnet Capital ProjectsCape Town Container Terminal

Electrical Workmanship and Installation SpecificationDocument No.:H500206-1-413-E-SP-0006-01- JV

Contract Number: H500206-CPC031A

Rev. C Electrical Material, Workmanship and Installation Specification Page 2 of 104

TABLE OF CONTENTS

1. PURPOSE OF THIS DOCUMENT ............................................................................................. 10

2. INTRODUCTION ..................................................................................................................... 11

2.1 PROJECT OVERVIEW..........................................................................................................11

3. SCOPE ..................................................................................................................................... 11

3.1 SCOPE OF WORK ...............................................................................................................113.1.2 Inclusion ..................................................................................................................133.1.3 Responsibility for plant and material...........................................................................13

4. ABBREVIATIONS .................................................................................................................... 14

4.1 ABBREVIATIONS................................................................................................................14

5. REGULATIONS AND APPLICABLE DOCUMENTS ................................................................... 15

5.1 LEGISLATIVE DOCUMENTS.................................................................................................155.2 REFERENCES .....................................................................................................................15

5.2.2 Project Documents....................................................................................................165.2.3 Project Drawings and Schedules ................................................................................17

6. SERVICE CONDITIONS .......................................................................................................... 17

6.1 AMBIENT/ENVIRONMENT CONDITIONS ..............................................................................176.2 ELECTRICAL CONDITIONS .................................................................................................18

6.2.1 Existing 11.75 kV Distribution ....................................................................................186.2.2 Existing 550 V Distribution.........................................................................................186.2.3 Existing 400 V Distribution.........................................................................................186.2.4 Electrical Installation conditions .................................................................................18

1. SECTION A: EQUIPMENT SELECTION AND WORKMANSHIP............................................... 19

1. EQUIPMENT SELECTION REQUIREMENTS............................................................................ 19

1.1 INSTALLATION OBJECTIVES...............................................................................................191.2 EQUIPMENT SELECTION CRITERIA.....................................................................................191.3 MAINTAINABILITY .............................................................................................................191.4 EQUIPMENT CORROSION PROTECTION..............................................................................201.5 EQUIPMENT ABRASION PROTECTION.................................................................................201.6 EQUIPMENT REDUNDANCY ................................................................................................201.7 VENDOR PACKAGES ...........................................................................................................20

2. CONSTRUCTION CONSTRAINTS............................................................................................ 20

2.1 ELECTRICAL SAFETY..........................................................................................................202.2 CABLE ROUTES..................................................................................................................202.3 MEASUREMENTS................................................................................................................212.4 TESTING AND INSTALLATION DATA ...................................................................................21

3. SAFETY REQUIREMENTS........................................................................................................ 21

3.1 GENERAL...........................................................................................................................213.2 EQUIPMENT SELECTION AND RATING ................................................................................213.3 ENCLOSURE CLASSIFICATIONS ..........................................................................................22





3.3.1 IP Code ....................................................................................................................223.4 IDENTIFICATION ON LABELLING OF DANGER AREAS ..........................................................233.5 EQUIPMENT IDENTIFICATION............................................................................................24

3.5.1 General Requirements ...............................................................................................243.5.2 Safety Labelling ........................................................................................................243.5.3 Securing of Labels.....................................................................................................243.5.4 General Labelling ......................................................................................................24

3.6 LOCKOUT PROCEDURES.....................................................................................................24

4. PORTABLE ELECTRICAL APPLIANCES AND TOOLS .............................................................. 25

4.1 EARTH LEAKAGE UNITS .....................................................................................................254.2 FLEXIBLE CABLES AND CORDS ...........................................................................................25

5. EXCAVATION OF CABLE TRENCHES AND INSTALLATION OF CABLES IN TRENCHES........ 25

5.1 CABLE ROUTING AND CLEARANCE TO EXCAVATE. ..............................................................255.2 LOCATION OF TRENCH ......................................................................................................265.3 METHOD OF EXCAVATION..................................................................................................265.4 RISK OF COLLAPSE TO SIDES OF EXCAVATIONS.................................................................265.5 KEEPING EXCAVATIONS FREE OF WATER ...........................................................................265.6 EXCAVATION DEPTH AND ARRANGEMENT OF CABLES.........................................................26

5.6.1 Depth of Cable Trenches ...........................................................................................265.6.2 Width of Cable Trenches ...........................................................................................265.6.3 Trenching Configuration ............................................................................................265.6.4 Laying of Cables in Trenches .....................................................................................265.6.5 Covering In of Cables ................................................................................................26

5.7 MARKING OF CABLE ROUTES, CABLE MARKERS ..................................................................275.8 MATERIAL CLASSIFICATION...............................................................................................27

6. INSTALLATION OF CABLES NOT IN TRENCHES ................................................................... 27

6.1 CABLES CROSSING ROADS.................................................................................................276.2 CABLE IN TUNNELS............................................................................................................276.3 CABLES IN DUCTS .............................................................................................................276.4 CABLES PASSING THROUGH CONCRETE FLOORS OR FOUNDATIONS ...................................276.5 CABLE INSTALLATION ON RACKS OR TRAYS.......................................................................28

6.5.2 Cable straps .............................................................................................................286.6 GENERAL CABLE HANDLING...............................................................................................286.7 CABLE JOINTS ...................................................................................................................29

6.7.1 Low voltage cables (up to 1000V) ..............................................................................296.7.2 MV Cables - 6,6kV, 11kV ...........................................................................................296.7.3 Connections..............................................................................................................296.7.4 Phasing ....................................................................................................................29

6.8 TERMINATIONS .................................................................................................................296.8.1 M.V. Cable Terminations............................................................................................296.8.2 Mini-substations, Transformer M.V. terminal boxes and MV Switchgear. .......................29

6.9 SEALING OF CABLES ..........................................................................................................296.10 LABELLING OF CABLES ......................................................................................................296.11 CABLE GLANDS (UNLESS SPECIFIED IN THE BILL OF QUANTITIES) .....................................30

6.11.1 Indoor Areas, MCC Rooms and Substations ................................................................306.11.2 Outdoor Areas. .........................................................................................................306.11.3 Hazardous Areas .......................................................................................................30

7. INSTALLATION OF ELECTRICAL EQUIPMENT ...................................................................... 30





7.1 GENERAL...........................................................................................................................307.2 MV SWITCHBOARDS ..........................................................................................................307.3 MINI-SUBSTATIONS AND TRANSFORMERS .........................................................................31

7.3.1 TRANSFORMERS SAFETY INSTALLATION, OPERATION AND MAINTENANCE ................317.4 LIGHT FITTINGS................................................................................................................32

7.4.1 Light fittings and socket outlets in Substations............................................................327.5 PROTECTION OF EQUIPMENT AFTER ERECTION .................................................................327.6 EARTHING.........................................................................................................................33

7.6.1 Substations...............................................................................................................337.7 CABLES .............................................................................................................................33

7.7.1 Armoured cables (LV below 1000V)............................................................................337.7.2 MV cables (XLPE) ......................................................................................................337.7.3 General ....................................................................................................................33

7.8 LIGHTNING PROTECTION ..................................................................................................347.8.1 Buildings and metal structures ...................................................................................34

8. CONDUIT................................................................................................................................. 34

8.1 GENERAL...........................................................................................................................348.2 SURFACE CONDUIT INSTALLATIONS ..................................................................................34

9. WELDING................................................................................................................................ 35

9.1 GENERAL...........................................................................................................................359.2 ELECTRODES.....................................................................................................................35

10. METHOD OF FIXING RACK AND OTHER SUPPORT STEELWORK......................................... 35

10.1 WELDING ..........................................................................................................................3510.2 USE OF HILTI STUDS.........................................................................................................3610.3 BOLTS, NUTS AND WASHERS .............................................................................................3610.4 UNISTRUT.........................................................................................................................36

11. LOW VOLTAGE MATERIAL...................................................................................................... 36

11.1 MATERIALS - GENERAL ......................................................................................................3611.2 WORKMANSHIP - GENERAL ................................................................................................37

11.2.2 Screws, Springs, Pivots, etc. ......................................................................................3711.2.3 Bolts, Studs, Nuts and Washers .................................................................................3711.2.4 Installation of Switchboard ........................................................................................38

12. TESTING AND ENERGISING .................................................................................................. 38

12.1 GENERAL...........................................................................................................................3812.2 SPECIFIC TESTS REQUIRED ...............................................................................................3912.3 PRESSURE TESTING OF MV CABLES ...................................................................................3912.4 LV CABLES (600/1 000 VOLTS) ...........................................................................................3912.5 LV DISTRIBUTION SWITCHGEAR........................................................................................3912.6 TRANSFORMERS................................................................................................................3912.7 FIELD EQUIPMENT.............................................................................................................4012.8 TEST EQUIPMENT..............................................................................................................4012.9 TESTS ON EQUIPMENT USING TEST VOLTAGES EXCEEDING 1000 VOLTS ............................4012.10 TEST CERTIFICATES ..........................................................................................................4012.11 CHECKING THE COMPLETED INSTALLATION.......................................................................4112.12 COMMISSIONING AND ENERGISING OF EQUIPMENT...........................................................41





12.12.1 Defects Found During Commissioning ........................................................................4112.13 TECHNICAL DOSSIER.........................................................................................................41

1. SECTION B: ELECTRICAL SPECIFICATIONS ......................................................................... 43

1. ELECTRICAL COMPONENTS AND DEVICES........................................................................... 43

1.1 GENERAL...........................................................................................................................431.2 CODES AND STANDARDS ...................................................................................................431.3 SWITCHES ........................................................................................................................43

1.3.1 General ....................................................................................................................431.3.2 Lighting Switch .........................................................................................................441.3.3 D.P. Switch for Appliance ..........................................................................................441.3.4 Time Switch..............................................................................................................441.3.5 Switch Exposed to Weather .......................................................................................44

1.4 SOCKET OUTLET................................................................................................................451.4.1 General ....................................................................................................................451.4.2 Integral Switch for Socket Outlet ...............................................................................451.4.3 Weatherproof Socket Outlet.......................................................................................451.4.4 Plug .........................................................................................................................451.4.5 Socket Outlet for Different Voltage System .................................................................451.4.6 Sockets within Station ...............................................................................................451.4.7 Installation of Socket.................................................................................................461.4.8 Floor Mounted Socket Outlets ....................................................................................461.4.9 Industrial Type Socket Outlet and Plug.......................................................................46

1.5 INSULATED TERMINAL BLOCK............................................................................................461.6 TELEPHONE OUTLET..........................................................................................................471.7 OUTDOOR BELL PUSH BUTTON ..........................................................................................471.8 REMOTE INDICATOR UNITS ...............................................................................................471.9 PHOTOCELL DEVICE ..........................................................................................................471.10 SUPPLY POINT WITH SEPARATE SUPPLY AUTHORITY METER..............................................47

2. ELECTRICAL REQUIREMENTS FOR PACKAGED MECHANICAL EQUIPMENT ....................... 47

2.1 SCOPE...............................................................................................................................472.2 CODES AND STANDARDS ...................................................................................................482.3 DESIGN FEATURES ............................................................................................................48

2.3.1 General ....................................................................................................................482.3.2 Electricity Supply.......................................................................................................482.3.3 Storage and Operating Conditions..............................................................................492.3.4 Access for Maintenance .............................................................................................492.3.5 Interchangeability and Standardisation.......................................................................492.3.6 Component Design....................................................................................................49

2.4 ELECTRICAL COMPONENTS................................................................................................492.4.1 General ....................................................................................................................492.4.2 Protective Devices.....................................................................................................502.4.3 Switchgear ...............................................................................................................502.4.4 Termination ..............................................................................................................502.4.5 Instruments..............................................................................................................50

2.5 CONSTRUCTIONAL FEATURES............................................................................................512.5.1 Surface Finish Process...............................................................................................512.5.2 Equipment Protection ................................................................................................512.5.3 Accessories...............................................................................................................52

2.6 CABLING AND WIRING.......................................................................................................522.6.1 Design......................................................................................................................52





2.6.2 Terminal Blocks ........................................................................................................53

3. EARTHING AND BONDING..................................................................................................... 53

3.1 SCOPE...............................................................................................................................533.2 CODES AND STANDARDS ...................................................................................................543.3 EARTHING MATS ...............................................................................................................54

3.3.1 Main Earthing Terminal .............................................................................................553.3.2 Test Link ..................................................................................................................553.3.3 Earthing and Protective Conductors............................................................................553.3.4 Main Equipotential Bonding Conductor .......................................................................563.3.5 Supplementary Bonding Conductor ............................................................................573.3.6 Earthing Conductor ...................................................................................................573.3.7 Fixing Accessories .....................................................................................................583.3.8 Earthing Cable Colour Identification ...........................................................................58

4. LIGHTNING PROTECTION SYSTEM....................................................................................... 59

4.1 SCOPE...............................................................................................................................594.2 CODES AND STANDARDS ...................................................................................................594.3 SYSTEM REQUIREMENTS ...................................................................................................594.4 CONSTRUCTION AND MATERIALS ......................................................................................60

4.4.1 Air Termination.........................................................................................................604.4.2 Test Joint .................................................................................................................614.4.3 Earth Termination .....................................................................................................614.4.4 Spacer Saddle...........................................................................................................614.4.5 Connection to Earth Termination................................................................................624.4.6 Bonding to Other Services .........................................................................................624.4.7 Joint in Conductors ...................................................................................................624.4.8 Testing.....................................................................................................................62

5. ELECTROMAGNETIC COMPATIBILITY .................................................................................. 62

5.1.1 Definition..................................................................................................................625.1.2 Performance .............................................................................................................62

5.2 SCOPE...............................................................................................................................635.2.1 Luminaires................................................................................................................635.2.2 Motor operated equipment including ..........................................................................635.2.3 Power Distribution.....................................................................................................635.2.4 Control Systems/microprocessor based system ...........................................................635.2.5 Third Party Equipment...............................................................................................63

5.3 STANDARDS ......................................................................................................................635.4 GENERAL REQUIREMENTS .................................................................................................64

5.4.1 Certification ..............................................................................................................645.4.2 Interference Considerations .......................................................................................655.4.3 Electromagnetic Interference (EMI)............................................................................655.4.4 Management ............................................................................................................665.4.5 Submittals ................................................................................................................67

1. SECTION C: PLANT AND MATERIAL ...................................................................................... 68

1. INTRODUCTION ..................................................................................................................... 68

2. GENERAL WORKS DESCRIPTION .......................................................................................... 68

3. HARBOUR MAIN INTAKE SUBSTATION ................................................................................ 70





3.2 Install and Commission new miniature substation MSS – 433 - 02.........................................713.2.2 Decommission Existing 11kV Switchboard A................................................................713.2.3 Decommission Existing 11kV Switchboard B................................................................713.2.4 New 11 kV switchboard 433-SGM-01..........................................................................713.2.5 Decommission Existing PFC 1 ....................................................................................723.2.6 Decommission Existing PFC 2 ....................................................................................723.2.7 Decommission Existing 400 V Battery Chargers...........................................................723.2.8 New 400 V Battery Chargers......................................................................................723.2.9 New Patch panels .....................................................................................................72

4. ETHERNET COMMUNICATION –SCADA, METERING & PROTECTION.................................. 72

4.1.2 Fibre optic pilot cable and terminations ......................................................................72

5. MV RETICULATION................................................................................................................. 74

5.1.2 Harbour Main Intake Substation to 501 substation. .....................................................745.1.3 Harbour Main Intake Substation to 502 substation. .....................................................745.1.4 Fibre optic cable .......................................................................................................75

6. Berth 501 Substation............................................................................................................. 75

6.1.2 New 11 kV switchboard 313-SGM-01..........................................................................756.1.3 New 1000 kVA, 11.75/0.4 kV Transformer 313- TRF-01...............................................756.1.4 New 400 V Main Distribution Board 313-MDB-01.........................................................766.1.5 New 400 / 230 V lighting Distribution Board 313-LDB-01 .............................................766.1.6 New Patch panel .......................................................................................................76

7. BERTH 502 SUBSTATION....................................................................................................... 76

7.1.2 New 11 kV switchboard 313-SGM-02..........................................................................767.1.3 New 1000 kVA, 11.75/0.4 kV Transformer 313- TRF-02...............................................777.1.4 New 400 V Main Distribution Board 313-MDB-02.........................................................777.1.5 New 400 / 230 V lighting Distribution Board 313-LDB-02 .............................................777.1.6 New Patch panels .....................................................................................................77


8.1.2 New 11 kV switchboard 333-SGM-01..........................................................................788.1.3 Existing 800 kVA, 11.75/0.4 kV Transformers T2 and T5 .............................................788.1.4 New 400 V Main Distribution Board 333-MDB-01.........................................................798.1.5 New 400 / 230 V lighting Distribution Board 333-LDB-01 .............................................798.1.6 New Patch panels .....................................................................................................798.1.7 Existing 11 kV Switchboard........................................................................................798.1.8 Existing Transformer T3 ............................................................................................798.1.9 Existing 400 V board .................................................................................................808.1.10 Existing 400 V Battery Charger ..................................................................................80


9.1.2 New 11 kV switchboard 343-SGM-01..........................................................................809.1.3 Existing 1250 kVA, 11.75/0.4 kV Transformers T2 and T5............................................819.1.4 New 400 V Main Distribution Board 343-MDB-01.........................................................819.1.5 New 400 / 230 V lighting Distribution Board 343-LDB-01 .............................................819.1.6 New Patch panels .....................................................................................................819.1.7 Existing 11 kV Switchboard........................................................................................829.1.8 Existing Transformer T1 ............................................................................................829.1.9 Existing 400 V board .................................................................................................829.1.10 Existing 400 V Battery Charger ..................................................................................82






10.1.2 New 11 kV switchboard 353-SGM-01..........................................................................8210.1.3 Existing 800 kVA, 11.75/0.4 kV Transformers T2 and T5 .............................................8310.1.4 New 400 V Main Distribution Board 353-MDB-01.........................................................8310.1.5 New 400 / 230 V lighting Distribution Board 353-LDB-01 .............................................8310.1.6 New Patch panels .....................................................................................................8410.1.7 Existing 11 kV Switchboard........................................................................................8410.1.8 Existing Transformer T1 ............................................................................................8410.1.9 Existing 400 V board .................................................................................................8410.1.10 Existing 400 V Battery Charger ..................................................................................84


11.1.2 New 11 kV switchboard 363-SGM-01..........................................................................8511.1.3 Existing 800 kVA, 11.75/0.4 kV Transformers T2 and T5 .............................................8511.1.4 New 400 V Main Distribution Board 363-MDB-01.........................................................8511.1.5 New 400 / 230 V lighting Distribution Board 363-LDB-01 .............................................8611.1.6 New Patch panels .....................................................................................................8611.1.7 Existing 11 kV Switchboard........................................................................................8611.1.8 Existing 400 V board .................................................................................................8611.1.9 Existing 400 V Battery Charger ..................................................................................86

12. HIGH MASTS LIGHTING......................................................................................................... 86

13. RTG POWER KIOSKS.............................................................................................................. 87

14. REEFER RETICULATION......................................................................................................... 88

14.2 REEFER CONTAINER KIOSK................................................................................................8814.3 BEKANOVA 70W HPS BULKHEAD LUMINAIRE ......................................................................88

15. FIRE PROTECTION BARRIERS............................................................................................... 89

16. SUBSTATION NOTICES AND SAFETY SIGNS ........................................................................ 89

17. GENERAL................................................................................................................................. 90

18. EXCLUSIONS........................................................................................................................... 91

1. SECTION D: INSPECTION AND TESTING.............................................................................. 92

1. INTRODUCTION ..................................................................................................................... 92

2. FACTORY ACCEPTANCE TESTS .............................................................................................. 92

3. SIITE ACCEPTANCE TEST....................................................................................................... 92

4. FINAL SYSTEM ACCEPTANCE................................................................................................. 92

1. SECTION E: DELIVERY AND INSTALLATION ........................................................................ 93

1. DELIVERY ............................................................................................................................... 93

2. STORAGE................................................................................................................................. 93

3. INSTALLATION ....................................................................................................................... 93





1. SECTION F: WARRANTY, SPARES, MAINTENANCE AND TRAINING ................................... 94

1. WARRANTY............................................................................................................................. 94

2. SPARES ................................................................................................................................... 94

3. MAINTENANCE ....................................................................................................................... 95

4. TRAINING............................................................................................................................... 95

1. SECTION G: ELECTRICAL DRAWINGS.................................................................................. 96





1. PURPOSE OF THIS DOCUMENT

This document covers the Electrical Installations at the port of Cape Town and should be read in

conjunction with the Bill of Quantities and the specifications issued by the employer for the electrical

Installation as detailed herein and the “ Employer’s Works Information”, H500206-CPC031.

It defines the standards of materials and equipment, installation and ancillary work to be employed in

the electrical installation contract or sub contract.





2. INTRODUCTION

As part of Transnet National Ports Authority’s Container Terminal Expansion Project for the Port of Cape

Town, the port is upgrading the existing Harbour Main, Berth 600, Berth 602, Berth 603 and Berth 604

substations and building two new Berth 501 and Berth 502 substations. The upgrade includes the

replacement of the existing 11.75kV switchgear, Installation of Miniature substations and transformers,

Installation of new Power Factor Correction equipment, Installation of new 11kV cables from Harbour

Main to the new 500 series substations, Installation of 400 V main distribution boards in the substations

and 110V DC supply systems. The new network infrastructure will have a new SCADA and Metering

System.

2.1 PROJECT OVERVIEW

Harbour Main Substation is supplied with four (4) x 11.75kV cable Incomers, operated in parallel, from

Eskom’s Salt River Substation. Each Incomer is equipped with 2 x 240mm2 XLPE cables. Two new

substations, 501 and 502, will be built to cater for the new reefer loads. The 2 x 500 series and 4 x 600

series substations will be supplied in a closed ring configuration from Harbour Main Substation via 2 x

240mm2 XLPE cables per feeder.

3. SCOPE

3.1 SCOPE OF WORK

This specification covers the Employer's requirements for the following equipment to be supplied,

delivered, installed and commissioned at the Port of Cape Town as detailed in the Employer's Works

Information H500206-CPC031-:

3.1.1.1 MV Cables

3.1.1.2 LV Cables

3.1.1.3 11.75/0.4 kV Outdoor Miniature Substations and indoor Transformers (install only)

3.1.1.4 400 V Main Distribution Boards in Substations

3.1.1.5 400 V Refrigerated Containers (Reefers) Power Kiosks

3.1.1.6 400 V Rubber Tyre Gantry (RTG) Socket Outlets (Plug Points)

3.1.1.7 High Masts Lighting Luminaries

3.1.1.8 Earthing and bonding

In addition to the above, the following will be undertaken:

3.1.1.9 Swinging of existing MV cables from the old panels into the new panels in the existing

Harbour Main and the 600 series substations,





3.1.1.10 Disconnection and decommissioning of existing electrical equipment in the refurbished

substations, and,

3.1.1.11 Removal from substations decommissioned electrical equipment and transportation to

designated storage area within the port.

Therefore, the works to be carried out by the Contractor shall include, but not be limited to the following

items of work as summarised below:

3.1.1.12 Refurbishment of the existing Harbour Main Intake11.75/0.4 kV Substation

3.1.1.13 Building new 501 11.75/0.4 kV Substation

3.1.1.14 Building new 502 11.75/0.4 kV Substation

3.1.1.15 Refurbishment of existing 600 11.75/0.4 kV Substation




3.1.1.19 Receiving, storing and safe custody of all Employer supplied Plant,

3.1.1.20 Supply, delivery, storing and safe custody of Contractor supplied Plant and Material,

3.1.1.21 Installation of Employer supplied 11 /0.4 kV Miniature substations and transformers,

3.1.1.22 Supply and installation of medium voltage (MV) and low voltage (LV) cables,

3.1.1.23 Supply and installation of Substation Main LV Distribution Boards,

3.1.1.24 Supply and installation of LV Lighting Distribution Boards in substations,

3.1.1.25 Supply and installation of LV Auxiliary Power Boxes for the Rubber Tyre Gantry (RTG)

cranes,

3.1.1.26 Supply and installation of MV and LV cable joints and terminations,

3.1.1.27 Excavations, trenching and backfilling of cable trenches,

3.1.1.28 Supply and installation of earthing and lightning protection systems,

3.1.1.29 Supply and installation of bulkhead lighting Luminaries on reefer gantries,

3.1.1.30 Supply and installation of refrigerated containers (Reefers) socket outlet points,

3.1.1.31 Supply and installation of sundry support steel and bracketry (Stainless Steel),

3.1.1.32 Swinging of MV and LV cables from the old panels to the new panels,

3.1.1.33 Supply, delivery, installation and termination of fibre optic cable between the various

substations patch panels for relay protection purposes

3.1.1.34 Testing and commissioning the new installation

3.1.1.35 Decommissioning of electrical equipment from the plant

3.1.1.36 Removal of decommissioned electrical equipment from the plant

3.1.1.37 Transportation of decommissioned electrical equipment from the substations /plant to the

designated storage location.

The Contractor shall acquaint himself with the contents of this Scope of Work, the Employer’s Works

Information document number H500206-CPC031 and associated Specifications and must conform to all

the required Schedules. The Contractor shall clearly state any deviations from the Schedules and remains





fully responsible to check (and advise accordingly of given requirements during his design) for

correctness and compatibility.

3.1.2 Inclusion

The following items are included under the Scope of Work for this Contract and the annexures are as

indicated in the Employer’s Works Information document number H500206-CPC031

3.1.2.1 All civil works required for successful installation of the equipment.

3.1.2.2 Earthing and Lighting protection system including earth bars, finials, stand-off insulators,

etc,

3.1.2.3 Polypropylene cable trench protective tiles, Danger Tape and Cable Route Markers,

3.1.2.4 25 mm “open ended” 316 Stainless Steel Conduit and Accessories,

3.1.2.5 Hot Dipped Galvanised Angle Iron Droppers, Cable and Equipment Supports,

3.1.2.6 316 Stainless Steel sundry nuts, bolts washers, etc,

3.1.2.7 6 mm Aluminium “Vastrap” cover plates,

3.1.2.8 Fire resistant barriers on cable openings in walls and cable slots in substation floors,

3.1.2.9 Electrical Notices, Safety Signs, brass padlocks, lock-out tags,

3.1.2.10 Any other items including small consumables required to complete the whole of the Works to

the satisfaction of the Project Manager,

3.1.2.11 Removing of existing switchgear and associated equipment and transportation to a

designated storage location.

3.1.2.12 Supply, delivery, installation, relocation and termination of MV cables.

3.1.2.13 Supply, delivery, installation, relocation and termination of LV cables.

3.1.2.14 Supply, delivery, installation and termination of fibre optic cable between the various

substations for relay protection purposes.

3.1.3 Responsibility for plant and material

The Contractor shall perform the following with respect to Plant and Materials procured by the Contractor for the Works: 3.1.3.1 All necessary test certificates to be included,

3.1.3.2 All Plant and Materials to be safely offloaded on site and safely secured,

3.1.3.3 All Plant and Materials to be inspected for damage on arrival at site,

3.1.3.4 All performance and guarantees shall be in favour of the Employer, as specified in the Employer

Specifications and SANS Standards prior to hand over.





3.1.3.5 The Contractor shall provide all necessary spares and consumables to the Employer. The

Contractor shall provide the recommended spare parts – each spare part shall be supplied

complete with corresponding data sheet/material certificate, instructions for safe storage and

installation manual. Returnable Schedule T2.2 – 15 must be completed and submitted with

Tender Document.

3.1.3.6 The Project Manager will approve the list of spares and consumables.

4. ABBREVIATIONS

4.1 ABBREVIATIONS

AC Alternating Current

ACB Air Circuit Breaker

AFA Automatic Fire Alarm

ATS Automatic Transfer Switches

AVR Automatic Voltage Regulation

BS British Standards Organisation

CIBSE Chartered Institution of Building Services Engineers (UK)

DC Direct Current

DIN Deutsche Industrie Normen

ECS Environmental Control System

ELU Earth Leakage Unit

ESD Electrostatic discharge

FS Fire Services

ISO International Standards Organisation

LSOH Low Smoke Zero Halogen

MCB Miniature Circuit Breaker

MCC Motor Control Centre

MCCB Moulded Case Circuit Breaker

OHS Act Occupational Health and Safety Act, Act 85 of 1993

RH Relative Humidity

RMU Ring Main Unit

SANS South African National Standards

SABS South African Bureau of Standards

SAIDSA South African Intruder Detection Services Association





SP Single Pole

TP Triple Pole

TPN Triple Pole + Neutral

TTA Type-tested assembly

VCB Vacuum Circuit Breaker

XLPE Cross-linked Polyethylene

COID Compensation for Occupational Injuries and Diseases

5. REGULATIONS AND APPLICABLE DOCUMENTS

5.1 LEGISLATIVE DOCUMENTS

Unless otherwise specified in this Material and Workmanship Specification, all equipment and installations

shall comply with the following:

5.1.1.1 The Occupational Health and Safety (OHS) Act, Act 85 of 1993,

5.1.1.2 The National Construction Regulations of 2003,

5.1.1.3 Water Act (Act 36 of 1998),

5.1.1.4 Hazardous Substances Act (Act 15 of 1973),

5.1.1.5 Environment Conservation Act (Act 73 of 1989),

5.1.1.6 COID Act,

5.1.1.7 The local municipal by-laws and regulations, as well as the regulations of the local supply

authority,

5.1.1.8 The Standard Regulations of any government department or public service company where

applicable,

5.1.1.9 The local Fire Regulations,

5.1.1.10 Independent Communications Authority of South Africa (ICASA) Regulations.

5.2 REFERENCES

5.2.1.1 National & International Documents

5.2.1.2 The equipment, services and installation shall comply with the mandatory requirements of:

5.2.1.3 SABS/SANS Code of Practice which refers to SANS 10142, the wiring of premises - Part 1: Low

voltage installations,

5.2.1.4 SANS10400: The application of the National Building Regulations

5.2.1.5 SANS 10198 part 1-11: Code of Practice – The selection, handling and installation of electric

power cables of rating not exceeding 33kV.





5.2.1.6 NRS 002-1990 : Graphical symbols for electrical diagrams.

5.2.1.7 SANS 10313-2004 : The protection of structures against Lightning

5.2.1.8 SANS 10199-2004 : The design and installation of Earth Electrodes.

5.2.1.9 SANS 1200A : Civil Engineering Construction: General1986

5.2.1.10 SANS 9001:2000/ISO 9001:2000 Quality management systems - Requirements Edition 3

5.2.1.11 MANELEC-S-006 : Street Lighting

5.2.1.12 Should material and apparatus used comply or be in accordance with the standard of any

other recognised standards institution, this shall be clearly stated at the time of tender.

5.2.1.13 Upon being requested to do so by the Engineer the Supplier / Subcontractor shall supply a

certificate of a recognised Research Laboratory or Bureau of Standards for materials used.

5.2.1.14 Material and equipment shall comply in respect of quality, manufacture, tests and

performance with the aforementioned standards or alternatively also to the current

specification of at least one (1) of the following standards institutes:

• The British Standards Organisation (BS).

• The International Standards Organisation (ISO).

• Die Deutsche Industrie Normen (DIN).

5.2.1.15 When referring to the aforementioned specifications, the abbreviations, BS, ISO and DIN

will be stated. When a specific specification number is specified, the latest applicable issue

and amendment shall be applicable.

5.2.1.16 Imported materials shall comply with the requirements of the appropriate SABS/SANS or

BS/IEC specification although these materials need not necessarily bear the SABS/SANS

mark.

5.2.2 Project Documents

The provisions and requirements of the following specifications apply to the works. They form an integral

part of this specification as provided in the Employer’s Works Information document number H500206-

CPC031. Where national standards are referred, it is the Contractor's responsibility to obtain the latest

copies of these standards and to be familiar with them.

Item Document number Name

1 HMG-DM-STD-002 Contractor Documentation Submittal Requirements

2 HMG-DM-STD-004 Data Books and Manuals Standard

3 HMG-HS-STD-001 Health and Safety Plan and Specification

4 HMG-IR-M-001 Industrial Relations Functional Execution Plan

5 HMG-IR-POL-003 Industrial Relations Policy and Management Plan

6 HMG-EM-STD-001 Standard Environmental Specification

7 H500206-1-100-L-SP-0001-JV Project Environmental Specification for Cape Town





8 HMG-EM-M-002 Construction Environmental Management Plan

9 HMG-QM-STD-001 General Quality Requirements for Suppliers and Contractors

12 H500200-0-000-E-SP-0003 Transnet Projects Specification: General Electrical Plant

13 H500200-0-000-E-SP-0009 Transnet Specification for Testing and Commissioning of

Electrical Plant

14 H500200-0-000-E-SP-0020 Transnet Specification for the MV and LV Cable Supply

H500200-0-000-E-SP-0021 Transnet Specification for the LV Electrical Installation to

Buildings

15 H500200-0-000-E-SP-0022 Transnet Specification for LV Main Distribution Boards

16 H500200-0-000-E-SP-0023 Transnet Specification for the MV and LV Cable Installation

17 H500200-0-000-E-SP-0026 Transnet Specification for the Marine Program, Corrosion

Protection

18 H500200-0-000-E-SP-0024 Transnet Specification for Marine Program, Miniature

substations

19 H500200-0-000-E-SP-0028 Transnet Specification for the Marine Program, oil filled

transformer

20 H500200-0-000-E-SP-0029 Transnet Specification for LV Lighting Distribution Boards

21 HMG-HS-GN-003 HMG Guideline for Cranes and Lifting equipment

22 HMG-HS-GN-015 HMG Guideline for Permit to Work

23 HMG-HS-GN-017 HMG Guideline for Electrical Safety

Table 1: List of project Standards and Specifications

5.2.3 Project Drawings and Schedules

See appendix B of this document

6. SERVICE CONDITIONS

The equipment shall be designed and rated for continuous operation under the following conditions:-

6.1 AMBIENT/ENVIRONMENT CONDITIONS

• Altitude : Sea level.

• Ambient temperature : -5ºC to +40ºC (daily average +35ºC).

• Relative humidity : As high as 86%.

• Lightning conditions : Severe, with a maximum lightning ground flash

density of 11 flashes per km² per annum.

• Atmosphere : Salt laden and corrosive industrial atmosphere.





6.2 ELECTRICAL CONDITIONS

6.2.1 Existing 11.75 kV Distribution

• 11 000 Volt Nominal

• 3-phase, 3-wire, 50Hz

• System neutral earthed via NEC/NER combination

6.2.2 Existing 550 V Distribution

• 550/317 Volt Nominal (Transformer no load voltage)


• System neutral solidly earthed

6.2.3 Existing 400 V Distribution

• 400/230 Volt Nominal (Transformer no load voltage)


• System neutral solidly earthed

6.2.4 Electrical Installation conditions

• The primary system of supply will be three phase, 11.75kV, 50Hz.

• The voltage may vary within the range of 95% to 105% of the nominal and all

equipment installed shall be suitably rated.





1. SECTION A: EQUIPMENT SELECTION AND WORKMANSHIP

1. EQUIPMENT SELECTION REQUIREMENTS

1.1 INSTALLATION OBJECTIVES

The electrical equipment shall be designed, engineered and or selected to:

1.1.1.1 Provide a safe working environment for personnel and equipment. 1.1.1.2 Minimise the environmental impact 1.1.1.3 Be designed as a “twenty five year plant” with low levels of maintenance and operating

costs. 1.1.1.4 Be cost effective, with the lowest life cycle costs 1.1.1.5 Provide a reliable electrical installation based on sound engineering utilising as far as

practicable concepts which have been tested and proven. 1.1.1.6 Integrate with the existing installations 1.1.1.7 Incorporate advanced technology practices

1.2 EQUIPMENT SELECTION CRITERIA

Equipment selection shall be based on the following criteria, in order of importance:

1.2.1.1 Technical suitability – Fit for intended use/purpose 1.2.1.2 Life cycle cost, including the efficient use of electrical energy 1.2.1.3 Capital cost 1.2.1.4 Standardisation 1.2.1.5 Supplier support

1.3 MAINTAINABILITY

Wherever possible all equipment shall be selected such that:

1.3.1.1 It is standardised 1.3.1.2 It is proven technology for the application 1.3.1.3 It has built in self diagnostics 1.3.1.4 It is maintainable without the need for special tools and equipment.

Please note that Transnet Capital Projects has a responsibility to ensure that only client’s recommended or preferred items of plant are procured from the nominated/recommended manufacturers/suppliers. It is therefore imperative on the part of the Contractor to liase with or contact the project electrical engineer in this regard before submitting tender prices or prior to the procurement of any electrical equipment.

Contractor must clarify all technical matters and queries related to the electrical works before submission of their tenders.





1.4 EQUIPMENT CORROSION PROTECTION

All equipment and support brackets shall be painted according to the project’s corrosion protection

specification guideline. Where the integrity of the protection is compromised the appropriate measures

need to be implemented.

1.5 EQUIPMENT ABRASION PROTECTION

Due consideration shall be taken during the design phase to ensure that all materials are selected in such

a manner as to prolong the life of the equipment and combat the corrosive effects of the environment.

1.6 EQUIPMENT REDUNDANCY

Redundancy shall be provided at the main intake sub-station and all substations to ensure N-1

contingency conditions.

1.7 VENDOR PACKAGES

1.7.1.1 Shall be designed to the requirements of this specification and shall utilise the same equipment as is selected for the entire plant.

1.7.1.2 Shall conform to the project guidelines 1.7.1.3 Shall include the safety considerations and requirements as detailed herein

2. CONSTRUCTION CONSTRAINTS

2.1 ELECTRICAL SAFETY

The Contractor or his subcontractors are under no circumstances permitted to enter any permanent or

temporary substation without the prior notice and attendance of the Supervisor.

The Employer's Isolation, Lock-Out and Safety Procedures will be implemented. No equipment shall be

de-energised or energised without the permission of the Project Manager or his duly appointed

representative.

2.2 CABLE ROUTES

The drawings showing the proposed cable route listed in the "Schedule of Drawings" shall not be taken to

show the precise final cable route. The Contractor shall within 30 days after being awarded the Contract

carry out a final route survey, which shall include digging test holes, and using the routes shown on the

drawings as a general guide, to determine a suitable route.

The Contractor shall submit details of the cable routes selected in final survey to the Project Manager for

approval. No excavation of any section of the cable route shall commence until the Project Manager has

authorised the commencement of work on the section concerned.

In the case of any deviation by the Contractor from the proposed cable route or joint locations as shown

in the relevant drawings, the Contractor must submit an amended copy of the drawing showing all

alterations to the proposed route to an accuracy of +/- 0.5m on either side of the actual location of the

cable or joints in question.





2.3 MEASUREMENTS

All measurements for payment purposes shall be made jointly by representatives of the Contractor and

Employer and shall be agreed / approved by both parties.

Measurements of trench width and height shall be made to the nearest 50mm and shall not take into

account subsidence or unnecessarily large excavations. No allowance shall be made where trenches have

to be widened at the bottom to accommodate cables, cable joint pits and protection slabs.

2.4 TESTING AND INSTALLATION DATA

All tests on completed cables shall be carried out in the presence of a representative of the Employer.

Not less than 14 working days notice of the Contractor's intention to carry out such tests shall be given to

the Project Manager.

On completion of the jointing and termination of cables, the 6.35 / 11KV cables are to be subjected to

the test laid down in paragraph E-1.4 of Appendix E of SANS 1339 and the low voltage type cables to be

tested for insulation and loop resistance.

The anti-electrolysis insulation of each 6.35KV cable run complete, shall withstand for 1 minute, a test

voltage of 10KV D.C., applied from the cable armouring to earth. The bedding shall withstand a test

voltage of 4KV D.C. between screen and armouring for 1 minute.

The Contractor shall on completion of the tests submit three copies of all test certificates. The costs of all

the tests mentioned above shall be borne by the Contractor.

The Employer reserves the right to carry out any further tests deemed necessary itself, using either the

Contractor's instruments and equipment, or its own, or both. The costs of such tests shall not be

charged to the Contract.

3. SAFETY REQUIREMENTS

3.1 GENERAL

No compromise will be permitted with respect to safety of personnel or equipment. The onus rests with

the Contractor to ensure that the requirements of the Occupational Health and Safety Act, and the latest

amendments thereto, are fully complied with.

3.2 EQUIPMENT SELECTION AND RATING

Equipment design, specification and selection shall be such that the highest attention is paid to personnel

and equipment safety. For this reason, equipment shall be conservatively rated and shall be selected

based on proven design. Under no circumstances shall equipment be selected to perform a duty in excess

of the manufacturer's ratings and the ratings specified in this General Specification. The ratings of

equipment specified in this General Specification shall take precedence over the manufacturer's ratings,

where they are more onerous.





3.3 ENCLOSURE CLASSIFICATIONS

Equipment shall be selected and specified to provide safe enclosures for the most onerous environment

that it shall be required to operate under. In general all equipment enclosures shall provide at least IP54

degree of protection when closed and IP2x classification when normal access doors are open. Equipment

located indoors in clean environments may have enclosures with classification IP43, provided prior

approval is obtained from the Project Manager.

Where enclosures are likely to be subjected to direct hosing down, the enclosure classification suitable for

the duty shall be negotiated with the supplier of the equipment. The enclosure shall then be IP65.

3.3.1 IP Code

The IP Code defined in international standard IEC 60529 classifies the degrees of protection provided against the intrusion of solid objects (including body parts like hands and fingers), dust, accidental contact, and water in electrical enclosures. It consists of the letters IP (for "international protection rating", sometimes also interpreted as "ingress protection rating") followed by two digits and an optional letter.

The digits ('characteristic numerals') indicate conformity with the conditions summarized in the tables below. Where there is no protection rating with regard to one of the criteria, the digit is replaced with the letter X.

3.3.1.1 First digit

The first digit indicates the level of protection that the enclosure provides against access to hazardous parts (e.g., electrical conductors, moving parts) and the ingress of solid foreign objects.

Level Object size protected against Effective against

0 — No protection against contact and ingress of objects

1 >50 mm Any large surface of the body, such as the back of a hand, but no protection against deliberate contact with a body part

2 >12.5 mm Fingers or similar objects

3 >2.5 mm Tools, thick wires, etc.

4 >1 mm Most wires, screws, etc.

5 dust protected Ingress of dust is not entirely prevented, but it must not enter in sufficient quantity to interfere with the satisfactory operation of the equipment; complete protection against contact





6 dust tight No ingress of dust; complete protection against contact

3.3.1.2 Second digit

Protection of the equipment inside the enclosure against harmful ingress of water.

Level Protected against Details

0 not protected —

1 dripping water Dripping water (vertically falling drops) shall have no harmful effect.

2 dripping water when tilted up to 15°

Vertically dripping water shall have no harmful effect when the enclosure is tilted at an angle up to 15° from its normal position.

3 spraying water Water falling as a spray at any angle up to 60° from the vertical shall have no harmful effect.

4 splashing water Water splashing against the enclosure from any direction shall have no harmful effect.

5 water jets Water projected by a nozzle against enclosure from any direction shall have no harmful effects.

6 powerful water jets Water projected in powerful jets against the enclosure from any direction shall have no harmful effects.

7 immersion up to 1 m Ingress of water in harmful quantity shall not be possible when the enclosure is immersed in water under defined conditions of pressure and time (up to 1 m of submersion).

8 immersion beyond 1 m

The equipment is suitable for continuous immersion in water under conditions which shall be specified by the manufacturer. NOTE: Normally, this will mean that the equipment is hermetically sealed. However, with certain types of equipment, it can mean that water can enter but only in such a manner that produces no harmful effects.

3.4 IDENTIFICATION ON LABELLING OF DANGER AREAS

During the design phase of any project, but more particularly during the construction phase, an exercise

shall be undertaken to identify dangerous or potentially dangerous equipment and/or areas and label

them appropriately.





3.5 EQUIPMENT IDENTIFICATION

3.5.1 General Requirements

In general, all safety labelling shall be graphic in nature to provide warning that can be understood by

illiterate persons and shall be capable of being understood by persons from all language groups.

3.5.2 Safety Labelling

All electrical equipment covers that contain electrical equipment shall bear warning labels indicating the

presence of live electrical equipment. The acceptable warning label shall be the yellow triangle with black

border and black lightning "bolt".

In addition removable covers shall bear the label ... "Isolate at ... before removing the cover" in English.

Warning labels shall have a red background with white lettering.

Each substation shall be provided with the following labels:

3.5.2.1 "Procedure in case of accidental contact with electrical equipment" 3.5.2.2 "Prohibition of unauthorised access and handling of electrical equipment" 3.5.2.3 "Procedure in the event of a fire" 3.5.2.4 "Emergency contact telephone numbers".

3.5.3 Securing of Labels

Labels shall be secured in such a manner that they cannot be easily removed. Where adhesive labels are

used attention shall be paid to the type of adhesive used to ensure that the labels will not peel off with

time. Double-sided adhesive tape is not acceptable.

3.5.4 General Labelling

All equipment shall bear a designation label-carrying wording that shall be clear and explicit in nature.

The equipment number should also be included on the label, usually in a secondary capacity.

Each outgoing circuit from switchgear shall indicate the device being supplied, both as the equipment's

name and its number.

Equipment shall also be labelled to indicate where it is supplied from, for example a lighting distribution

board would carry the label "Fed from Main Distribution Board - 313-MD-01". It is not acceptable to

state, "Fed from 313-MDB-01" only.

In particular, all LV switchgear and distribution boards shall be labelled in strict accordance with SANS

10142-1.

The equipment number shall be the minor part of the label.

3.6 LOCKOUT PROCEDURES

All individual electrical enclosures with access doors or covers shall be designed and selected so as to

provide facility for locking, by means of a multiple padlock system suitable for padlocks with a 5mm

diameter hasp, in the off / disconnected / out of service position. This requirement also applies to covers

held in place with square key type catches that provide access to live equipment.





Lockout of electrical equipment and motor starters must take place where a break in the power circuit is

ensured (i.e. feeder panel, MCC starter, etc). Field stop buttons must never be used for lockout

purposes.

It shall not be possible to lock equipment in the "ON" position.

HMGJV standard procedures together with the TNPA/TPT procedures must be adhered to.

4. PORTABLE ELECTRICAL APPLIANCES AND TOOLS

4.1 EARTH LEAKAGE UNITS

4.1.1.1 All electrical appliances and tools, working off 110 or 220 volt supply, must be protected by an earth leakage unit of 30 milliamp sensitivity, either of a portable or fixed type.

4.1.1.2 All 380 and 500 volt plug outlets for portable equipment (e.g. welding machines, concrete mixers, etc) must be protected by an instantaneous operating earth leakage unit of not greater than 250 milliamp sensitivity.

4.2 FLEXIBLE CABLES AND CORDS

4.2.1.1 All flexible cables and cords must have a separate continuous earth core. 4.2.1.2 No joints are allowed in these cables. 4.2.1.3 All cables must be fitted with an approved plug, suitably rated. 4.2.1.4 The termination of cables on plugs must be done by a qualified electrician. 4.2.1.5 Damaged plugs, cords or cables are not to be used. 4.2.1.6 The user of cables or cords is held responsible to report any damage or noticeable defect to

the Foreman electrician concerned. 4.2.1.7 Repairs to electrical cords, cables and plugs may only be done by a qualified electrician. 4.2.1.8 All electrical tools where possible shall be of the double insulated type and must be to the

approval of the Engineer.

NOTE : THE ENGINEER RESERVES THE RIGHT TO DISCONTINUE POWER SUPPLY IF IN HIS

OPINION ANY EQUIPMENT IS UNSAFE OR DOES NOT MEET THE CONDITIONS STIPULATED IN THIS

SPECIFICATION.

5. EXCAVATION OF CABLE TRENCHES AND INSTALLATION OF CABLES IN TRENCHES

5.1 CABLE ROUTING AND CLEARANCE TO EXCAVATE.

No excavation is to be commenced in an existing installation until authorisation has been given by the

Engineer who will provide the Contractor with details of existing buried services in the area concerned.

No installation should commence until such confirmation of the route has been obtained from the

Project Engineer.

Where obstructions are encountered which necessitate diversions of cables due to adjacent structures,

pipes, drains, etc. approval of such deviations shall be obtained from the Project Engineer.

The runs shall be selected to avoid exposure to drip or accumulation of liquids or high

temperatures.





5.2 LOCATION OF TRENCH

The exact location of each trench is to be approved by the Engineer.

5.3 METHOD OF EXCAVATION

The use of mechanical excavation machines will only be permitted when written approval has been

given to this effect by the Engineer.

5.4 RISK OF COLLAPSE TO SIDES OF EXCAVATIONS

Any trench of a greater depth than 1, 5 metres, or where ground conditions require, is to have the

side walls adequately shored up.

All precautions are to be taken to ensure that damage resulting from subsidence will not occur

adjacent to roads, railways, walls, sewers, drains, pipes or similar structures.

5.5 KEEPING EXCAVATIONS FREE OF WATER

The excavations shall be protected from flooding, and any water which occurs in the excavations

whether as a result of seepage, rain or other causes shall immediately be removed by baling, pumping

or other approved method, ensuring that damage does not occur to cables.

5.6 EXCAVATION DEPTH AND ARRANGEMENT OF CABLES

5.6.1 Depth of Cable Trenches

Minimum 600mm for low voltage cables and 900mm for medium voltage cables.

5.6.2 Width of Cable Trenches

The minimum width of the trench to be 500mm.

5.6.3 Trenching Configuration

Trenches are to be straight, Cut Square, and the bottom of a trench is to be level and free from

stones or hard projections.

The bottom of the trench is to be covered by a layer of fine sifted soil, at least 50mm thick, before

any cables are laid.

5.6.4 Laying of Cables in Trenches

Cables shall be laid such that a minimum gap of 25mm is maintained between the outside edges of all

cables.

5.6.5 Covering In of Cables

Cables shall be covered with a layer of fine stone-free soil not less than 75mm thick. Thereafter the

following procedure is to be followed:

5.6.5.1 Medium and low voltage cables

5.6.5.1.1 The trench is to be filled in with local soil. The soil is to be firmly stamped down. 5.6.5.1.2 Any surplus soil is to be piled on top of the trench. 5.6.5.1.3 One month later, any subsidence must be made good and the trench levelled off.





5.7 MARKING OF CABLE ROUTES, CABLE MARKERS

A PVC cable warning marker tape is to be installed in each trench running the complete length of the

trench and be laid 300mm above the cables.

Concrete cable markers are to be placed at a maximum of 50 metre spacing along the entire length of

the cable and at every change in direction of the cable.

5.8 MATERIAL CLASSIFICATION

The removal and disposal of all materials encountered while carrying out excavation shall be included

in one of the classifications of excavation as described in the Bill of Quantities.

The decision of the Engineer as to the classification of the material shall be final and binding, and any

objections as to the classification must be made in writing before the excavations have been

backfilled.

6. INSTALLATION OF CABLES NOT IN TRENCHES

6.1 CABLES CROSSING ROADS

Cables are to cross roads via one of the following methods, as indicated on the drawings:

6.1.1.1 Cable tunnels with reinforced roofs and sturdy walls 6.1.1.2 Culverts, where the cables are in ducts. 6.1.1.3 Culverts or reinforced concrete pipes with a minimum diameter of 150mm where cables are

laid directly into the ground. NOTE: Where reinforced concrete pipes are used, separate pipe is to be used for each individual cable having bitumen jute serving (outer sheath). 6.1.1.4 Suitable pipe sleeves made from steel or PVC with a minimum diameter of 110mm. NOTE: The Engineer will specify the number of cables per sleeve. 6.1.1.5 On large diameter cables, only one per sleeve will be allowed. 6.1.1.6 Analogue and telephone cables are to be in sleeves separate to electrical cables. 6.1.1.7 After cables have been installed, each sleeve is to be sealed with a weak concrete mix.

6.2 CABLE IN TUNNELS

Cables shall be installed on racks and supported by brackets along the sidewalls of the cable tunnel.

6.3 CABLES IN DUCTS

6.3.1.1 Cables are to be neatly laid parallel to each other. 6.3.1.2 The position of medium and low voltage cables is to be approved by the Engineer. 6.3.1.3 Entrance of cables into the duct from the side shall be through a sleeve of adequate size

(inside diameter of the sleeve is to be at least twice the outside diameter of the cable). 6.3.1.4 After the cable has been installed, the sleeve is to be sealed with a weak concrete mix.

6.4 CABLES PASSING THROUGH CONCRETE FLOORS OR FOUNDATIONS

Where cables pass through a concrete floor or foundation, etc., they will be passed through

galvanised steel or high density PVC pipe that is at least 50mm larger than the cable diameter.

In the case of floors, this pipe will extend from 60mm below to 360mm above the slab.





NOTE: Not more than one long radius bend of up to 90 degrees may be used in any unbroken

pipeline. The maximum overall length of such pipe section is not to exceed 30 metres. The minimum

radius of a 90 degree bend shall be 15 times the cable outside diameter.

6.5 CABLE INSTALLATION ON RACKS OR TRAYS

Racks to be adequately supported to carry the overall weight of the maximum number of cables for

which such rack is designed.

Racks are to be supported at every point where the route of the rack changes direction.

Single angle iron cable supports may be used under the following conditions:

6.5.1.1 Not more than 2 cables per single angle iron 6.5.1.2 The angle iron shall be of adequate dimensions to support and protect the cable/s.

Where cables are exposed and mechanical protection is warranted, a solid sheet metal cover shall be

bolted into position.

Power and control cables may be run on a common rack, providing they are separated and/or

identifiable to the approval of the Engineer.

Cables are to be clamped or strapped in separate voltage groups.

A maximum of three cables may be bulk clamped or strapped providing they are of similar diameter.

Spacing of cable clamps on cable racks must not exceed:

OVERALL CABLE DIA. mm. MAX.SPACING - HORIZONTAL MAX.SPACING -VERTICAL

Not exceeding 15mm. 350mm 450mm

15 - 22mm 400mm 525mm

22 - 32mm 450mm 600mm

Exceeding 32mm 500mm 700mm

NOTE:

6.5.1.3 Vertical in the above table means a cable rack rising at 90 degrees to the horizontal. 6.5.1.4 Horizontal means a rack running in the horizontal plane, with the rack mounted such that it

is vertical or edgewise.

6.5.2 Cable straps UV stabilised PVC straps will be allowed. Heavier cables (> 25mm² 4 core) will be strapped using

stainless steel straps.

6.6 GENERAL CABLE HANDLING

Cables are to be laid in trenches or fixed on racks directly off the drum.

Cables of long lengths shall be pulled with a cable stocking or pulling eye and pulled over cable rollers

and corner rollers.

Under no circumstances shall cable be pulled whilst in contact with the ground.





In pulling cables, the manufacturer's specifications regarding the pulling force, bending radius, etc.,

shall be observed. Suitable drum jacks are to be provided.

Cables are to be transported around site on the cable drums provided by the cable manufacturer and

on a custom built cable drum trailer and haulage vehicle.

6.7 CABLE JOINTS

Type of joints to be used on:

6.7.1 Low voltage cables (up to 1000V) Approved standard stock, cast type joint boxes or moulded resin joints are to be used.

The armouring to be carried through externally on cast joint boxes and internally with moulded resin

joints.

6.7.2 MV Cables - 6,6kV, 11kV Appropriate Raychem, Sigmaform or 3M jointing kits, approved by the Engineer.

6.7.3 Connections All cables with conductors over 70mm² are to be hexagonal crimped.

6.7.4 Phasing Colour-to-colour or number-to-number connections must be maintained throughout the length of

cables.

6.8 TERMINATIONS

Where cable cores are connected to stud type terminals, crimp-on lugs are to be used. Hexagon type

crimping to be used on conductors with area more than 70mm².

6.8.1 M.V. Cable Terminations.

Raychem, Sigmaform or 3M termination kits to be used on MV cables.

6.8.2 Mini-substations, Transformer M.V. terminal boxes and MV Switchgear.

Heat shrink-terminations of Raychem, Sigmaform or 3M manufacture are to be used for crutch and

cable tails in the terminal boxes of these units unless other terminating systems e.g. "DYSCON" or

similar are being used.

6.9 SEALING OF CABLES

Cable ends shall be sealed immediately after they have been cut.

A lead seal end cap or PVC `heat shrink' end cap may be used.

6.10 LABELLING OF CABLES

All cable cores shall be fitted with the correct marking ferrules as detailed on cable schedule and inter-

connection diagrams.

Every cable shall have a stainless steel "DYMO" type tape attached on each end on which shall be

punched the cable number shown on the cable schedule.

NOTE: As built cable schedules are part of the Special Conditions of Contract.





6.11 CABLE GLANDS (UNLESS SPECIFIED IN THE BILL OF QUANTITIES)

6.11.1 Indoor Areas, MCC Rooms and Substations

6.11.1.1 CCG type BW cable glands or equivalent to be used with shroud.

6.11.2 Outdoor Areas. 6.11.2.1 CCG posiguard type - or equivalent - no shroud.

6.11.3 Hazardous Areas 6.11.3.1 Glands to be used in such areas will be specified in the Bill of Quantities.

7. INSTALLATION OF ELECTRICAL EQUIPMENT

7.1 GENERAL

7.1.1.1 All equipment shall be installed as per the manufacturer's instructions and to the approval of the Engineer.

7.1.1.2 All equipment shall be carefully levelled and adjusted for operation. 7.1.1.3 Precautions shall be taken to counter vibrations likely to be transmitted by plant machinery. 7.1.1.4 As vibrations are unlikely to be fully evident until machinery is operating, checks for

vibrations shall be made during commissioning. 7.1.1.5 Any unsatisfactory conditions detected shall be reported in writing to the Project Engineer

for remedial action. 7.1.1.6 Equipment shall not be grouted in position prior to inspection and approval by the Project

Engineer. 7.1.1.7 Neither compressed air nor cotton waste shall be used for cleaning purposes. 7.1.1.8 Distribution boards and control boards which are wall mounted shall have horizontal centre

lines approximately 1 500mm above floor level. 7.1.1.9 All equipment is to be protected throughout erection against the ingress of moisture, dust,

dirt and foreign bodies. 7.1.1.10 Equipment to be stored shall be given adequate covering. The contractor shall be

responsible for any damage or loss of goods handed over to him and he will be required to replace, free of charge, any damaged or lost items.

7.1.1.11 Light switches, socket, power and plug outlets shall be installed as indicated on the relevant drawings. Where it is not practical to mount the equipment as shown, amended instructions will be issued by the Engineer.

7.1.1.12 Mounting heights of all other equipment will depend on the circumstances but will also be subject to the written approval of the Engineer.

7.1.1.13 Bare earth wires shall be taped at the terminals. 7.1.1.14 A clearance of 2m or better shall be left between switches or socket outlets and water taps.

7.2 MV SWITCHBOARDS

Normally the manufacturer of any MV switchboards will install them as is the case in this regard (ABB).

In certain circumstances, the Installation Contractor may be requested to install this equipment. This

will be set out in the Bill of Quantities.

Under no circumstances shall any MV switchboard be energised by the contractor without the

permission of the Engineer and a signed hand-over certificate from the equipment manufacturer.





7.3 MINI-SUBSTATIONS AND TRANSFORMERS

These are to be installed complete including connecting MV and LV cable with specified termination

kits and glands, neutral bushing to earth, transformer body to earth, auxiliary wiring to protective

devices, neutral to earth CT for earth leakage protection, and installing dehydrating breather and

padlock to transformer bay and warning boards when the transformer is energised.

7.3.1 TRANSFORMERS SAFETY INSTALLATION, OPERATION AND MAINTENANCE

Please observe the following and any other safety advices before installation, commissioning and

maintenance:

7.3.1.1 Never work on transformers or any installed electrical equipment alone,

7.3.1.2 Do not move or lift a transformer without applying adequate equipment and safety

precautions,

7.3.1.3 Do not make any connections which do not comply with the rating plate,

7.3.1.4 Do not apply abnormal mechanical strain on the terminals,

7.3.1.5 Do not reconnect when the transformer is energized,

7.3.1.6 Do not attempt to change tap setting while the transformer is energized,

7.3.1.7 Do not energize or perform maintenance on the transformer without proper earth

connection,

7.3.1.8 Do not operate the transformer without alarm and monitoring systems connected,

7.3.1.9 Do not remove any enclosure panels while the transformer is energized,

7.3.1.10 Do not tamper with interlocks, alarms and control circuits,

7.3.1.11 Be aware of possible need for magnetic field protection,

7.3.1.12 Perform a final inspection prior to energizing:

7.3.1.12.1 All external connections have been made properly,

7.3.1.12.2 All connections are tight and secure,

7.3.1.12.3 All accessory circuits are operational,

7.3.1.12.4 All tap connections are properly positioned,

7.3.1.12.5 The neutral and earth connections have been properly made,

7.3.1.12.6 Fans – if supplied – are operational,

7.3.1.12.7 Proper clearance is maintained from high voltage bus to terminal equipment,

7.3.1.12.8 The correct transformer ratio exists for units with internal terminal boards,

7.3.1.12.9 All windings are free from un-intended earths. A relevant megger is recommended,

7.3.1.12.10 There is continuity in all windings,

7.3.1.12.11 There is no dust, dirt or foreign material on core and coils (dry-type transformers),

7.3.1.12.12 There is no visible moisture on or inside the core and coils (dry-type transformers),

7.3.1.12.13 All plastic wrappings are removed from the core and coils (dry-type transformers),

7.3.1.12.14 All shipping members have been removed,

7.3.1.12.15 There are no obstructions in or near the openings for ventilation,





7.3.1.12.16 No tools or other articles are left inside or on top of the core, coils, tank or

enclosures,

7.3.1.12.17 All protective covers are closed and tightened,

7.3.1.13 Comply with any instructions supplied by the transformer manufacturer,

7.3.1.14 Comply with relevant Internal Control Regulations.

7.4 LIGHT FITTINGS

All light fittings shall be installed in accordance with project drawings. However, due care and

attention should be given to accessibility for maintenance and lamp replacement. All fittings shall be

complete with lamp of correct size and type.

Floodlights shall be orientated at night and then securely clamped, to ensure a uniform distribution of

light over the area to be illuminated:

Where suitable terminals are not provided within fittings the contractor shall provide suitable

connectors.

In general, all fittings should be fixed directly onto steelwork by means of suitable support brackets.

The design to be approved by the Engineer if not detailed in the project drawings.

Light fittings to have a minimum 3 way junction box associated with each. Connection to fitting, if

suspended, to be flexible. Any unused gland holes to be fitted with stoppers. The Contractor must

take particular care that the I.P. rating of any fitting is maintained during installation.

Fittings installed in Hazardous Areas will have the correctly specified Cable Glands, and the contractor

must ensure that the manufacturer's installation instructions are adhered to.

The Engineer shall be notified in writing of the date on which lighting circuits are energised and the

fittings in a particular plant area are put into service. The fitting and lamp guarantee period shall

commence from this date. This date shall be recorded in writing by the contractor and agreed by the

Engineer. This date will not necessarily be deemed to be a hand-over.

7.4.1 Light fittings and socket outlets in Substations

When the Installation Contractor is requested to install lighting and socket outlets in substations and

Control Rooms, the Contractor is to obtain from the Engineer an indication of the standard that will be

required. This will normally be via drawings.

These will indicate whether surface mounted conduit with wiring will be required, and specify whether

PVC or metal conduit is to be used, as well as the colour in the case of PVC conduit.

The Contractor may be required to phase the fittings.

These items are to be agreed before the work is commenced.

7.5 PROTECTION OF EQUIPMENT AFTER ERECTION

It will be the responsibility of the contractor to ensure that all equipment erected by him is protected

against accidental damage that could be caused by other ongoing erection activities of all disciplines.





The contractor will therefore be called upon, to make good any damage caused to equipment due to

lack of adequate precautions being taken, as described above with any costs being for his account.

7.6 EARTHING

7.6.1 Substations

Standard details will normally be shown on drawings and may include the following:

7.6.1.1 Earthing rods or an earthing mat is to be installed at all transformers which are to connect to the main substation earth conductor in a ring circuit through 1 x 120 mm² stranded conductors. The Engineer to approve the earthing method.

7.6.1.2 The main earthing conductor (the substation earth) to which the earth rods or earth mats, and the bonding of the substation equipment connects, shall consist of a solid copper bar of approximately 500 x 50 x 10mm dimensions mounted on the substation wall on stand off insulators.

7.6.1.3 The conductor size for bonding of all metallic equipment in the substation is to be approximately 25 x 4mm solid copper or 120mm², PVC sheath stranded copper conductor.

7.6.1.4 Branch tee-offs from the main earthing conductor to the earth mats, transformer star points and bonding of equipment are to be: I) brazed in the case of solid to solid conductor connections. ii) A lug to be used in the case of stranded to solid conductor connections. iii) Soldered in the case of stranded to stranded conductor connections.

7.6.1.5 All cable trays, racking, conduit, trunking, cable sheaths and armouring, substation screens and all other metal work connected with wiring (other than the current carrying parts) are to be bonded to earth.

7.6.1.6 The Contractor is to ensure that a suitable earth is provided. This shall be by use of a suitable specification, or notification that an earthing specialist is to be used.

Overall impedance of less than 5 ohms to the general mass of earth should be obtained.

7.7 CABLES

7.7.1 Armoured cables (LV below 1000V) The armouring is to be bonded to earth using mechanical compression glands to clamp the armouring

at each end of the cable.

NOTE. Single core armoured cables will have the armouring bonded to earth at one side of the cable

only. This will normally be done at the sending end.

7.7.2 MV cables (XLPE) Armouring is to be made off in normal manner using suitable gland. Separate 120mm² green PVC

sheathed conductor from substation or switchgear earth bar to the item of equipment is to be installed

in addition.

7.7.3 General

For 3 phase 3 wire installations where 4 core cable has been specified, the fourth core (black) shall be

used as the earth conductor.

On 3 phase 4 wire installations, the fourth core (black) shall be used as the neutral conductor with a

separate suitably rated bare copper conductor used as the earth conductor.

NOTE: Under this contract 1-core x 120mmm² PVC copper sheathed conductor has been specified as

the earth conductor.





NOTE: Bare earth conductors buried in the ground shall be kept at least 600mm from buried cables

unless the cables are PVC sheathed overall. Insulated earth conductors are recommended where

stray D.C. traction currents or soil conditions could cause electrolytic corrosion.

All steel structures shall be bonded and earthed against static charges, in accordance with the

drawings, and independently of the earthing system for the electrical equipment.

Main earthing points shall be made of a suitable number of copper earth rods, driven to a suitable

depth. Earth mats or plates shall be as specified by the Engineer.

When the armour of a cable is earthed, the clamp used shall be of special design so that it will grip

firmly and permanently without damage to the insulation or to the metal sheath of the cable.

Where an earthing conductor is exposed to possible mechanical damage, it shall be protected by

means of a suitable conduit or pipe, preferably non-metallic.

Where earthing is carried out in acidic areas, all earth conductors shall be PVC insulated.

7.8 LIGHTNING PROTECTION

7.8.1 Buildings and metal structures

To provide for lightning protection the contractor will install earth electrodes at the corners of

buildings and metal structures. All structures must be so earthed at two opposite corners and at

intervals of not more than fifty (50) metres. The steel cladding and metal structures are then bonded

to the earth electrode unless otherwise detailed on drawings.

8. CONDUIT

8.1 GENERAL

The conduit shall have a minimum diameter of 20mm and be cut square and clean before threading.

Threads shall be made using suitable conduit thread dies and the liberal application of cutting grease

or similar. The length of thread shall be such as to permit conduits to be firmly butted together in

couplings and hard against the shoulders of threaded conduit box spouts with no thread exposed.

The ends of all cut lengths of conduit shall be reamed free from burrs and any loose swarf shall be

removed from inside the conduit.

Sockets, bends and fittings shall be of the same material as the conduit.

8.2 SURFACE CONDUIT INSTALLATIONS

All surface run conduits shall be of the galvanised type unless otherwise specified in the Bill of

Quantities. Conduit runs on the surface of walls, floors, ceilings, or in accessible ceiling voids, etc.,

shall be installed in a neat manner running generally with the building lines. The conduits shall be

vertically plumb and horizontally level as applicable. Bends in multiple runs of conduit shall be

matching. Other right angle bends shall be standard machine made. In all instances the installation

shall present a neat and workmanlike appearance.





Where open-ended conduit is used to support lighting cables, the ends shall be bushed.

Fixings of tubing shall be effected by spacer bar saddles. Light gauge saddles may be used for

general internal installations whilst heavy base saddles are to be used for external galvanised conduit

installations and industrial applications.

9. WELDING

9.1 GENERAL

Welding shall comply with the requirements of SABS Code of Practice 044, Welding.

Before any welding is carried out on an existing structure, the properties of the steel shall be

determined.

All welding shall be done by qualified welders who have been previously qualified by test in

accordance with the requirements of SABS 044 - Welding, and the contractor shall submit evidence of

such qualifications to the Engineer if called upon to do so. An operator shall require re-qualification if

he has not been engaged in metal welding for a period of three months or more, or when changing

type of material, or if there is a specific reason to question the welder's ability.

All welding shall be by the electric arc process unless oxyacetylene welding is specified.

The welding plant return clamp is to be at all times connected directly to the item being welded, to

prevent damage to any equipment by stray return currents.

The Engineer may direct the contractor to remove any inferior welding and/or direct the contractor to

cut test specimens from the welds which, in the Engineer's opinion, are of inferior quality. The

Engineer may direct that welds be nick broken or bent in his presence. Alternatively the contractor

may provide x-ray or other approved non-destructive tests on suspect welds with all test methods

being subject to the prior approval of the Engineer.

9.2 ELECTRODES

Electrodes shall be selected so that the resulting weldment is compatible with the design requirements

with respect to both strength and ductability.

10. METHOD OF FIXING RACK AND OTHER SUPPORT STEELWORK

The methods of fixing cable racks to plant steelwork will generally be specified in the Bill of Quantities.

The methods described below are some of the accepted methods.

10.1 WELDING

When welding as a method of fixing rack and support brackets and steelwork onto existing steelwork

is prohibited, this shall be indicated to the Contractor in the Scope of Work and the Bill of Quantities.





In such cases, all support steelwork requires to be attached to existing steelwork using the drill and

bolt method.

When welding as a method of fixing rack is allowed, the Contractor shall ensure that the specifications

for priming, patching, and painting of steelwork, and any other corrosion control prevention methods

required, are properly executed.

10.2 USE OF HILTI STUDS

This type of fixing may be permitted when welding is not allowed.

The contractor will be required to enforce all the necessary safety precautions that are required by the

Engineer and as laid down by the OSH Act.

10.3 BOLTS, NUTS AND WASHERS

10.3.1.1 Specified areas are to be stainless steel.

10.3.1.2 Non-specified areas to be galvanised.

10.4 UNISTRUT

10.4.1.1 All Unistrut to be hot dip galvanised. No stainless steel need be used.

10.4.1.2 All holes drilled in structural steel to be made good as detailed in the Painting and Corrosion

Specification issued with the Bill of Quantities.

11. LOW VOLTAGE MATERIAL

11.1 MATERIALS - GENERAL

11.1.1.1 All material incorporated in the Works shall be suitable for the duty concerned and shall be

new and of first class industrial quality, free from imperfections, and selected for long life and

minimum maintenance under the specific site conditions.

11.1.1.2 All equipment supplied shall be of current industrial quality, and of well-proven design.

11.1.1.3 As far as practicable, the use of electrically dissimilar metals in contact shall be avoided. If

this is not possible, the contact surfaces of one or both of the metals shall be electroplated or

the two metals shall be insulated from each other by an Approved method.

11.1.1.4 While the Contractor may offer alternatives to satisfy the above requirements for the

Engineer’s review in respect of certain components, the following general requirements shall

be observed unless otherwise stated:

•••• Steelwork: electro-galvanized sheet steel with a coating weight of not less than

60g/m² of surface i.e. 120g/m² on both sides, or hot-dip galvanized sheet steel with

a coating weight of not less than 300g/m² of surface i.e. 600g/m² on both sides.





•••• Insulating materials: Non-impregnated paper, fabric, wood or press-palm shall not be

used for insulating purposes.

11.1.1.5 The use of asbestos and asbestos based materials is not permitted.

11.2 WORKMANSHIP - GENERAL

11.2.1.1 All similar items of the TTA and their component parts shall be completely interchangeable. Spare parts shall be manufactured from materials to the same specification as the originals and shall fit all similar items of the TTA’s. Where machining may be needed before fitting renewable parts, the machining fits with their tolerances shall be shown on the drawings accompanying the instruction manuals.

11.2.1.2 All parts which are subject to wear or damage by dust shall be totally enclosed in dust-proof housings.

11.2.1.3 The TTA shall operate without excessive vibration and with a minimum of noise, and shall also operate without excessive temperature rise at the rated load conditions. The design and the whole construction shall satisfy all the following structural requirements as type tested and certified by a competent and independent internationally recognized testing authority:

Test Standard Severity

Shock IEC 68-2-27 Equivalent peak acceleration of 15g for a duration of 11ms

Bump IEC 68-2-29 Equivalent acceleration of 10g for a duration of 16ms, and 1000 Nos. of bump in each mutually perpendicular direction

Random Vibration IEC 68-2-36 Total r.m.s. acceleration of 0.26g for a frequency range from 10Hz to 150Hz

11.2.1.4 The style and finish of the workmanship shall be consistent throughout the Works.

11.2.2 Screws, Springs, Pivots, etc.

11.2.2.1 Use of iron and steel for screws, springs and pivots in instrument and electrical relays shall be avoided wherever possible. Steel screws when used shall be plated with zinc, chromium or cadmium, or when tolerance limitations preclude plating, shall be of corrosion-resistant steel.

11.2.2.2 Springs shall be of non-rusting material (e.g. phosphor bronze or nickel silver) where possible. Pivots or other parts for which non-ferrous material is unsuitable shall be of an Approved corrosion-resistant material.

11.2.3 Bolts, Studs, Nuts and Washers

11.2.3.1 All bolts, studs and nuts shall be to an Approved standard and to metric dimensions and shall

generally be of bright steel. Those subject to vibration, high temperature or pressure shall be

of high tensile material, and to the Approval of the Engineer.

11.2.3.2 Bolts, studs, nuts and washers shall be made of free machining quality stainless steel when

they are subject to frequent adjustment or removal, or when they are used for any

application subject to corrosion.





11.2.3.3 Bolts, studs and nuts shall be suitably machined. Rolled threads will be considered acceptable

if conforming to an Approved standard. Washers shall be provided under all nuts and bolt

heads where appropriate. Bolts and studs shall protrude by at least one thread pitch beyond

the outside face of nuts.

11.2.3.4 Jacking screws shall all be of high tensile steel with fine treads of an Approved form.

11.2.3.5 Nuts, bolts, tap-bolts, set pins and any other item subject to vibration shall be secured with

Approved locking devices.

11.2.4 Installation of Switchboard

11.2.4.1 Where the switchboard is delivered in more than one section, the sections shall be joined

together to form an integral unit.

11.2.4.2 The switchboard shall be installed with sides, front and back vertical and base and top level.

When the floor is uneven or not level, the base of the switchboard shall be packed up till

truly level before being grouted in position.

11.2.4.3 Before energising, each switch shall be thoroughly cleaned. Any loose pieces of packing

material or other foreign bodies shall be removed.

11.2.4.4 The metal casings and other non-current carrying metallic parts of the switchboard shall be

earthed. Unless otherwise specified the connection between the main switchboard and earth

electrode shall be by means of 50 x 10mm copper tape at both ends of LV switchboard.

11.2.4.5 The various cubicles housing the respective switch and ACB shall be so arranged as to give a

multi-tier arrangement and shall include a cabling and wiring chamber of ample dimensions

in which terminal blocks, cable boxes and gland plates can be located.

11.2.4.6 Connector or soldered ‘joints’ are not permitted in the secondary wiring which shall,

whenever possible, be grouped and laced together in a neat manner.

11.2.4.7 Each assembly shall be supplied complete with all operating handles, jigs, etc. required for the normal operation and inspection of all circuit breakers and switchgears of the assembly.

12. TESTING AND ENERGISING

12.1 GENERAL

12.1.1.1 The contractor shall be responsible, as part of his scope of work, to carry out testing and

pre-energisation checking of electrical equipment in accordance with methods and

procedures laid down hereunder.

12.1.1.2 The Contractor shall appoint a competent person to control all testing and checking activities.

This person shall report to and liase closely with the Project Site Engineer in order that

testing activities may be conducted and sequenced in a manner best suited to the

commissioning programme.

12.1.1.3 Defects revealed during testing and checking which are attributable to the contractor shall be

made good by the contractor without delay.





12.1.1.4 Where defects in free-issue supplied equipment are revealed, these should be reported to the

Project Site Engineer at an early date.

12.2 SPECIFIC TESTS REQUIRED

12.2.1.1 Testing of electrical equipment shall include, but not be limited, to the following:

12.2.1.2 DC pressure testing of MV cables, joints and terminations with a 5000Volt Megger.

12.2.1.3 Megger testing of 380V power cables using a 2000V hand wound Megger.

12.2.1.4 Continuity test and phasing out of all cables

12.2.1.5 Pre-energisation testing of transformers.

12.2.1.6 Testing of LV Distribution Switchgear

12.2.1.7 Testing and measuring of substation earth.

12.2.1.8 Proving correct mechanical operation of moving parts e.g. relays, limit switches, switch or contactor mechanisms, timing devices, etc.

12.3 PRESSURE TESTING OF MV CABLES

Each MV cable shall be tested after installation and before it is energised. Tests shall be carried out

after all terminations and joints have been completed. The AC and DC test voltages will be as per the

cable manufacturer's recommendations for such tests.

12.4 LV CABLES (600/1 000 VOLTS)

All LV cables shall be tested for insulation resistance before installation and after termination (before

connecting to apparatus) using a 2 000V DC insulation resistance tester. Insulation resistance values

of less than 200 megohms before installation shall be suspect and investigated.

The end-to-end DC resistance of cores of buried cables shall be measured and recorded in a test

certificate.

12.5 LV DISTRIBUTION SWITCHGEAR

After erection, all LV distribution switchboards and motor control centres shall be tested for insulation

resistance using a 2000V DC insulation resistance tester.

Phase to phase and phase to earth insulation resistance values of under 50 megohms shall be suspect

and investigated.

12.6 TRANSFORMERS

The MV winding of transformers shall be tested to earth using a 5000V DC insulated resistance tester

and the LV winding using a 2000V DC insulation resistance tester. Insulation resistance values of

under 500 megohms and 200 megohms for the HV and LV windings respectively shall be suspect and

investigated.





Buchholz relays shall be tested by air or Nitrogen injection. Nitrogen would be preferred.

Temperature relays, if fitted, shall be tested by checking the operation of alarm and trip contacts.

The contacts are to be set at the alarm and trip values as required by the Engineer.

Silica gel breathers shall be oil sealed to the required level and checked for dryness.

12.7 FIELD EQUIPMENT

12.7.1.1 All field equipment shall be checked in respect of mechanical operation of all moving parts, tightness of connection.

12.7.1.2 Testing shall be repeated each time an installation is disturbed e.g. carrying out of a cable joint.

12.7.1.3 Leakage currents shall be recorded on the test certificate.

The contractor shall ensure safety of personnel during testing operations and this shall include the

stationing of a person at the remote end of the cable under test. He shall also ensure that the cable

is properly discharged before authorising workmen to proceed with termination work.

Testing shall be carried out with the cable in its final position except for the individual cores on each

termination, which shall be moved away from their respective connection points.

Precautions shall be taken to ensure that the main busbars do not become energised during the

testing operations.

12.8 TEST EQUIPMENT

The contractor shall make available suitable staff, tools and testing equipment, including necessary AC

and DC pressure test sets, earth testers, multimeters and clip on type ammeters. Other specialised

test equipment that may be required will be provided at an agreed rate in accordance with Special

Conditions of Contract at the request of the Engineer.

12.9 TESTS ON EQUIPMENT USING TEST VOLTAGES EXCEEDING 1000 VOLTS

The Project Site Engineer will be responsible for authorising the Contractor to carry out these tests.

Any safety precautions as laid down or requested by the Engineer must be adhered to.

12.10 TEST CERTIFICATES

After completion of the tests detailed above, the contractor shall complete a test certificate showing

the results of the test.

Appendix to this specification gives details of the Project requirements in terms of test certificate

format.

Completed test certificates shall be handed to the Project Site Engineer within seven days of the test.

Failure to do so may result in rejection of the test data in which case the contractor would be required

to repeat the tests concerned at his expense.





12.11 CHECKING THE COMPLETED INSTALLATION

After each respective installation has been completed, the installation shall be thoroughly checked, by

the contractor, against the appropriate test certificate detailed in this specification.

Checking shall be carried out before testing commences.

Submission of the completed check sheet, to the Project Site Engineer, shall indicate that the

installation detailed on the respective check sheet/s is complete and ready for inspection and `punch

listing' by the Engineer.

12.12 COMMISSIONING AND ENERGISING OF EQUIPMENT

Pre-commissioning checks and commissioning of all electrical equipment, other than lighting circuits,

shall be the responsibility of the Engineer or his deputy.

It is probable that the Engineer will, from time to time, require assistance from the contractor. Upon

request therefore, the contractor shall make available, on a day work basis, suitable qualified staff to

assist the Engineer with commissioning activities.

Energization and de-energization is the responsibility of the port operator (TNPA/TPT)

12.12.1 Defects Found During Commissioning

12.12.1.1 Any defects found by the Engineer during the commissioning shall be rectified by the

contractor except where the defect is as a result of faulty manufacture by the supplier of the

equipment free-issued to the Contractor and providing that the defect is not as a result of

damage occurring during installation by the Contractor.

12.12.1.2 Defects found during commissioning on equipment supplied by the Contractor shall be

repaired by the Contractor as quickly as possible.

12.12.1.3 Where it is decided by the Engineer to request the contractor to repair or make good a

manufacturing defect the cost of such repairs shall be agreed and written up onto a site

instruction before the work is commenced.

12.13 TECHNICAL DOSSIER

Each major item of electrical equipment shall have associated with it a so-called "Technical Dossier"

which shall be filled with the order file for reference purposes, at project close out stage.

It shall contain, amongst other things, the following;

12.13.1.1 The Technical specification

12.13.1.2 Design calculations

12.13.1.3 Certified Vendor drawings

12.13.1.4 Protection and other settings, as well as the criteria and the relevant information against

which the settings were established





12.13.1.5 Factory test certificates

12.13.1.6 Site test certificates

12.13.1.7 Hand-over certificate

12.13.1.8 Certificate of Compliance

12.13.1.9 Vendor safety instructions

12.13.1.10 Operation and maintenance manuals

12.13.1.11 Details of operator training requirements

12.13.1.12 Recommended spares list

12.13.1.13 Recommended servicing instructions

12.13.1.14 Relevant drawings of concept

All of the above shall carry the written approval of the Project Manager.





1. SECTION B: ELECTRICAL SPECIFICATIONS

1. ELECTRICAL COMPONENTS AND DEVICES

1.1 GENERAL

Electrical devices and accessories shall meet the general requirements of SANS 10142 and BS5733.

Lighting switches, socket outlets and switches for electrical appliances shall be designed for flush

mounting. In conduit installations, they shall be mounted in steel or cast iron surface type galvanized

boxes. The front plate shall be metal-clad type for plant room.

Unless otherwise specified, metal boxes for the enclosure of electrical accessories in conduit system shall

be of 35mm depth, complying with SANS 10142 or BS 4662.

1.2 CODES AND STANDARDS

Electrical devices and accessories shall comply with the relevant latest version of the following standards

or equivalent national standards.

1.2.1.1 BS546 Specification for Two-pole and Earthing Pin Plugs, Socket-outlets and Socket-outlet

Adaptors

1.2.1.2 BS646 Specification for Cartridge Fuse-links (rated up to 5A) for AC and DC Service

1.2.1.3 BS1362 Specification for General Purpose Fuse-links for Domestic and Similar Purposes

1.2.1.4 BS1363 Specification for 13A Fused Plugs and Switched and Un-switched Socket-outlets

1.2.1.5 BS2950 Specification for Cartridge Fuse-links for Telecommunication and Light Electrical

Apparatus

1.2.1.6 SANS 60669-1:1998 Switches for household and similar fixed-electrical Installations Part 1:

General requirements

1.2.1.7 SANS 60309-1:2006 Plugs, socket-outlets and couplers for industrial purposes Part 1:

General requirements

1.2.1.8 BS5733 Specification for General Requirements for Electrical Accessories

1.2.1.9 SANS60529:2001 Degrees of protection provided by enclosures (IP Code)

1.3 SWITCHES

1.3.1 General Switches for domestic and similar purposes shall comply with SANS 10142 or BS3676. They shall be

mounted at a height of 1350mm above finished floor level unless otherwise specified.





1.3.2 Lighting Switch Lighting switches shall be of the microgap type suitable for used on AC circuits, and shall be of the quick

make-and-break type when used in DC circuits.

Lighting switches shall generally be 10amp, 15amp or 20amp depending on duty and according to SANS

10142, the wiring of premises – Part 1: Low voltage installations.

Lighting switches shall be single pole rated at 10amp minimum.

When lighting switches are mounted adjacent to one another, they shall be grouped in a single enclosure

(multi-way box) and shall share a common switch plate, subject to a maximum of three lighting switches

per single-gang plate.

Lighting switches, installed adjacent to a door shall be located on the handle side of the door and shall be

as near to the door as practicable.

1.3.3 D.P. Switch for Appliance Switches controlling appliances with heating elements or appliances permanently connected to the supply

shall be of double pole type with an integral pilot light, and shall have a rating not smaller than the

current capacity of the appliance being controlled. The front plate of each such switch shall be properly

engraved.

The pilot light shall be formed by a neon lamp with resistor and a red coloured lens.

Cooker switches shall comply with SANS 10142, BS4177 or BS3676 and be 45amp or 60amp double-pole

type, depending on duty. The switches shall be fitted with a 0.5W neon indicating lamp.

1.3.4 Time Switch Time switches shall be of self-starting, self-winding driven by synchronous motor or latest technology in

the market. They shall be of the plug-in type, and shall be housed in a metal enclosure provided with a

removal cover of clear plastic material.

The time switches shall be suitable for operation at 230V and the rated current shall be 20A unless

otherwise specified.

Time switches shall incorporate the following features:

1.3.4.1 A spring reserve of not less than 30 hours to drive the mechanism during electricity supply interruptions;

1.3.4.2 An easily replaceable cartridge fuse-link complying with BS646 or BS2950, inserted in the motor circuit;

1.3.4.3 An ON-OFF manual switch to enable the circuit to be controlled without affecting normal dial operation;

1.3.4.4 A 24-hour dial with at least two ON and two OFF levers and a single pole, single throw, switch.

1.3.5 Switch Exposed to Weather

Switches mounted outdoors, or in positions where they may be exposed to rain or water, shall have

watertight enclosures with IP65 in accordance with SANS60529. Alternatively they may be mounted

inside approved watertight enclosures.





1.4 SOCKET OUTLET

1.4.1 General 1.4.1.1 Unless otherwise specified, socket outlets shall be connected in a 13A ring main system or

shall be spur feeds. All socket outlets shall be of the shuttered type, complying with

SANS60884, VC8008 or BS1363 and shall accept two pole and earth round pin plugs and

have switches with a rocker type lever, either fully recessed or having a raised surround to

prevent inadvertent operation.

1.4.1.2 15A socket outlets shall be of the shuttered type, complying with SANS 10142, SANS 60884,

VC8008 or BS546 or BS1363, and shall accept two pole and earth round pin plugs and have

switches with a rocket type lever, either fully recessed or having a raised surround to prevent

inadvertent operation.

1.4.1.3 Heavy-duty socket outlets shall be 32amps or 63amps four-pole with earth connection,

complying with SANS60309-2. Unless otherwise specified, interlocked switch-fuses shall not

be required.

1.4.1.4 Emergency power points for Fire Services Department shall be 230V, 15A, single-phase

switched socket outlet with splash proof enclosures to IP64 or other type to the approval of

Fire Services Department.

1.4.2 Integral Switch for Socket Outlet All socket outlets shall be fitted with an integral switch. The integral switch shall be of single pole,

forming part of the same front plate as the socket outlet.

1.4.3 Weatherproof Socket Outlet Socket mount outdoor shall be waterproof type socket outlets. Waterproof type socket outlets shall

comply with SANS60309-2, provided with a push-on cap and cap retaining ring or a screw-on cap with

rubber gasket. The socket outlets shall have a degree of protection of at least IP65 to SANS60529.

1.4.4 Plug 1.4.4.1 Plugs for 13A socket outlets shall be fitted with a fuse suitably rated to suit the appliance

connected to it. In case the current rating of the appliance cannot be ascertained, a 13A fuse

shall be fitted.

1.4.4.2 Every plug shall be fitted with a cord grip which is so designed that no stress will be taken by

the terminals or the conductors of the flexible cable connected to it.

1.4.5 Socket Outlet for Different Voltage System Socket outlets and plugs for one voltage system shall not be interchangeable with those for use at other

voltage and/or frequency systems in the same installation.

1.4.6 Sockets within Station All the socket outlets shall be engraved with the voltage rating of ‘230V’ for all areas.





1.4.7 Installation of Socket 1.4.7.1 Sockets shall not be allowed in toilets.

1.4.7.2 Sockets on both sides of the wall shall not be mounted back to back, but shall offset

minimum 300mm.

1.4.7.3 Sockets shall be 2m away from water or gas pipes or sockets connected to another phase.

1.4.7.4 Unless otherwise specifies, socket outlets shall be mounted at a height of 1350mm above

finished floor level in kitchens and the like, and at a height of 300mm above finished floor

level in other locations. The mounting height of socket outlets installed in areas with wall

mounted bumper strips shall be co-ordinated with the Engineer to avoid any possible

clashing.

1.4.7.5 Unless otherwise specified, wiring shall be carried out in low smoke halogen free cable of

minimum conductor size of 2.5mm² carried in rigid trunking and/or conduit throughout.

1.4.7.6 Socket outlets intended for supplying fixed or stationery appliance shall be located as near as

possible to the appliance.

1.4.8 Floor Mounted Socket Outlets Floor mounting socket outlets shall comprise a recessed galvanized steel floor box, neoprene sealing

gasket, metal alloy plug cover cap and key, and shall be correctly set in the floor slab to ensure that the

screwed level adjustments set the unit with the finished floor level.

1.4.9 Industrial Type Socket Outlet and Plug 1.4.9.1 Industrial type socket outlet shall be rated at 16A, 32A, 63A or 125A as specified on the

drawing and shall comply with SANS 60309-2.

1.4.9.2 Socket outlets of rating 16A, 32A and 63A, TPN+E or DP+E shall be of splash proof

construction to IP44.

1.4.9.3 Socket outlet of rating 125A, DP+E or TPN+E, shall be of watertight construction to IP67.

1.4.9.4 Current carrying conductor including earthing conductor shall be made of brass, copper or

other suitable material.

1.4.9.5 Socket outlets and plugs shall have pilot pins and sleeves shorter than other sleeves and pins of

the unit such that pilot circuit makes last and break first.

1.4.9.6 Socket outlet shall be of TPN+E (3P+N+E) or 2P+E (DP+E) as specified on the drawings.

1.4.9.7 Industrial socket outlet shall be fed by radial circuit.

1.4.9.8 Socket outlet shall be provided with plug and be included in this Contract.

1.5 INSULATED TERMINAL BLOCK

1.5.1.1 The rated voltage of terminal blocks shall not be less than 415V between terminals and 240V

to earth.





1.5.1.2 Terminal blocks shall comprise brass connectors with screw connections, all contained within

a moulded block suitable for working temperatures up to 100°C.

1.5.1.3 Terminals shall be designed to clamp the conductor between metal surface with sufficient

contact pressure but without causing damage to the conductors. With the largest

recommended conductor in position, and tightly clamped, there shall be at least two full

threads of the screw engaging in the connector.

1.6 TELEPHONE OUTLET

Telephone outlets shall comprise a deep conduit box flush mounted in walls to SANS 10142 or BS4662.

The exact details of the mounting shall be referred to the room data sheets/requirements of the Contract.

1.7 OUTDOOR BELL PUSH BUTTON

Outdoor bell push buttons shall be weather proof, complying with SANS 10142 or BS3676 and with a

degree of protection not less than that defined by characteristic IP54 in accordance with SANS60529.

1.8 REMOTE INDICATOR UNITS

Remote indicator units other than those on control/indicating panel shall be of LED indicator type and

mounted on cover plates of stainless steel with matt satin finish and be suitably labelled.

1.9 PHOTOCELL DEVICE

Photocell devices shall have an accuracy of within ±5% and no moving parts. The photocell unit shall be

weatherproof constructed to IP54 and fitted with a manual switch of 3 positions (ON-AUTO-OFF).

Additional circuitry shall be provided to achieve switching due to lightning or other short period changes

in illumination. The photocell device shall be the fail-safe type with a range of switch on values between

50 lux and 1000 lux and an ON/OFF ratio of 1:1.5.

1.10 SUPPLY POINT WITH SEPARATE SUPPLY AUTHORITY METER

Separate neutral link shall be provided for the power supply device with separate Supply Authority meter,

e.g. TP+N MCCB, TP+N isolators, etc as the pre-meter main device.

2. ELECTRICAL REQUIREMENTS FOR PACKAGED MECHANICAL EQUIPMENT

2.1 SCOPE

This specification covers the general requirements for electrical design and construction of packaged

mechanical systems (equipment, components, materials, etc.) furnished as part of mechanical equipment

and associated ancillary systems.






All electrical systems shall be constructed, installed and tested in accordance with the relevant parts of

the latest version of the following standards or equivalent national standards.

2.2.1.1 The Occupational Health and Safety (OHS) Act, Act 85 of 1993;

2.2.1.2 SABS Code of Practice which refers to SANS 10142, the wiring of premises - Part 1: Low

voltage installations;

2.2.1.3 The National Building Regulations;

2.2.1.4 The local municipal by-laws and regulations, as well as the regulations of the local supply

authority;

2.2.1.5 The Standard Regulations of any government department or public service company where

applicable;

2.2.1.6 The local Fire Regulations;

2.2.1.7 TELKOM Regulations.

Material and equipment shall comply in respect of quality, manufacture, tests and performance with the

aforementioned standards or alternatively also to the current specification of at least one (1) of the

following standards institutes:

• The British Standards Organisation (BS).

• The International Standards Organisation (ISO).

• Die Deutsche Industrie Normen (DIN).

2.3 DESIGN FEATURES

2.3.1 General The equipment shall be designed for simplicity, safety, and reliability to give long continuous economical

service, with minimum maintenance and to facilitate rapid fault-diagnosis and parts replacement. Unless

otherwise specified, all individual items of equipment supplied shall be suitable for operation with at least

25 years service life for major electrical components and 7 years service life for major electronic

components under specified environmental conditions. The manufacturer shall demonstrate this, if

required, by submitting the service record of similar equipment elsewhere, or by records of

comprehensive type tests for rating and design.

Ratings of equipment mounted in enclosures shall take into consideration the heat dissipated by the

equipment and nearby components and the derating factors associated with the enclosure, switching

surges, power factor and other operational factors. Electrical equipment enclosures shall be arranged for

cables entering from above and below.

The surface temperature of any part which could be contacted accidentally shall not exceed 65°C.

2.3.2 Electricity Supply The low voltage electricity supply shall be 400V, three phase, four wire, 50Hz or 230V, one phase, 50Hz

and may vary within limits of plus and minus 6% of voltage and 2% of frequency.





Equipment shall operate satisfactorily for prolonged periods at +6%, -10% of the nominal voltage

without damage.

It is preferable to serve a packaged unit with a single power feeder at the system supply voltages

indicated above. Where power is to be utilized at different voltages from those listed or at more than one

voltage level, the transformation means for connections to the system supply voltages shall be provided.

2.3.3 Storage and Operating Conditions Equipment supplied shall be capable of withstanding any combination of the environmental ambient

conditions as specified in which it can be stored or operated at rated capacity without mechanical or

electrical damage or degradation of performance.

2.3.4 Access for Maintenance Components shall be sited such that easy access is provided for inspection, maintenance or repair

without dismantling other components.

Components mounted in layers requiring removal or desoldering of other components before gaining

access for maintenance or inspection will not be accepted.

Side mounted components will not be permitted unless these will not obstruct the access to the front

mounted components.

2.3.5 Interchangeability and Standardisation Equipment which performs similar functions shall, as far as possible, be of uniform type and manufacture

in order to simplify maintenance and stocking of spare parts. Corresponding parts shall be standard and

interchangeable. Manufacturer's standard designs shall be preferred.

2.3.6 Component Design `Volt-free' contacts shall be electrically isolated from the equipment and shall be used to complete

external control alarm or indication circuits.

Selectors shall not be used for on/off control unless otherwise specified.

Equipment provided with anti-condensation heaters shall be capable of operation with a 230V AC, one

phase power supply without damage should the heaters be left on continuously; otherwise automatic

control thermostat shall be incorporated. Heaters shall not cause any damage to equipment or wiring and

shall be protected independently with fuses mounted inside the enclosures at accessible locations.

The method of connection to equipment shall, as far as possible, not require highly skilled personnel nor

soldering and wire wrapping techniques. Where these are unavoidable, plug-in modular units shall be

used.

2.4 ELECTRICAL COMPONENTS

2.4.1 General Components shall be adequately rated and circuits shall be designed so that change of component

characteristics within the manufacturer's tolerances shall not affect the performance of equipment to be

supplied.





All control and indicating equipment shall be mounted on the front of the panel.

2.4.2 Protective Devices Suitable circuit protection shall be supplied for controls such that any one electrical fault does not affect

more than one unit or system. The protection shall be accomplished by circuit breaker or fuse. Circuit

breakers are preferable; however, fuses may be required by the application to provide the proper

coordination or protection to the circuit devices. Fuse bases and carriers for HBC fuses shall be of plastic

moulded insulating material and all live terminals and contacts shall be effectively shrouded. Fuse links to

BS88 shall be provided.

A disconnecting means shall be provided to permit servicing of individual systems or control components.

Where all power to a packaged unit is supplied by one main feeder, a main disconnecting means shall be

provided so that the entire package may be de-energized at one location. Where more than one motor

starter is in a common enclosure, separate disconnecting means for each motor shall be provided.

2.4.3 Switchgear MCCB’s shall comply with SANS60947-2 and shall incorporate core-balanced earth fault trip elements with

adjustable time delay of 0.5 sec. to 3 sec.

Fuse switches may be used for ratings up to 32A. For higher ratings, fuse switches shall be used.

Equipment shall comply with SANS60947-3.

MCB’s for power electrical equipment shall have a minimum breaking capacity of 6kA to BSEN60898.

2.4.4 Termination Stud terminals shall be provided at the motor for power supply. For external connections, terminal blocks

shall be provided.

Cable sockets shall be of annealed copper up to 57-60 maximum Brinell hardness. Terminal bases shall

be of polyester moulding or equal. Non-metallic compression glands for instrument cables shall be of

glass polyester or tufnol with neoprene rubber ring.

An earth terminal for stranded copper wire shall be provided for each panel.

All supply feeders, such as motor feeders, heater circuits, etc. shall include an equipment earthing cable

sized in accordance with the BS7430 and BS7671. Provisions for terminating the equipment earthing

cable shall be provided.

2.4.5 Instruments Instrument and associated components shall be fully tropicalised and enclosed in cases.

Indicating instruments shall have zero adjustment. Access to the terminals of instruments shall not

expose the working parts.

Instruments for integrated measurements (e.g. kilowatt-hour meters, flow counters, etc.) shall not reset

automatically on failure of electricity supply, accidental disconnection or reversal of connection. A secure





means shall be provided against inadvertent manual resetting by unauthorized personnel, while the

instrument is in or out of operation (e.g. by means of key-operated pushbutton or lever).

Instruments on cubicle front shall be flush-mounted without front fastenings. The finish of bezels and

cases shall be semi-matt black.

Scales for indicating instruments shall be so designed as to eliminate parallax error. The scale shall be

linear for flow indication. Instruments shall attain the specified accuracy without special calibration.

2.5 CONSTRUCTIONAL FEATURES

2.5.1 Surface Finish Process

2.5.1.1 Metallic Material Finish Machining and dressing shall be completed before galvanizing. Galvanizing shall be by the hot-dip process

to BS729: Part I.

Chromium shall not be electro-plated directly on to ferrous parts. Metallic components which need

chromium plating shall first be nickel plated to a minimum thickness of 0.03mm.

No parts likely to be in contact with oil shall be galvanized. Sherardized coatings or cadmium plated parts

shall not be used for outdoor equipment.

2.5.1.2 Rust Protection Cutting, drilling and de-burring of metal parts shall be completed with all traces of rust and grease

thoroughly removed prior to application of a zinc chromate or other approved rust inhibiting primer.

2.5.1.3 Painting At least two coats of corrosion resistant paint shall be applied on metal surfaces after phosphate

treatment. A durable matt or semi-matt finish shall be given for indoor equipment and gloss finish for

outdoor equipment. The minimum coating thickness shall be 75 micron.

2.5.2 Equipment Protection

2.5.2.1 Tropicalisation of Components Components shall be selected suitable for use in the climatic and environmental conditions as specified.

Alternatively components may be treated in accordance with established techniques to withstand the

specified conditions.

2.5.2.2 Environmental Protection Unless otherwise specified, tests conducted shall comply with BS2011.

The equipment shall be designed to prevent the entry of vermin and to minimise the entry of dust and

dirt. Adequate safe-guards shall be provided to prevent accidental contact with hot surfaces or electrically

live parts during operation and inspection of the equipment. Parts which can be worn or damaged by

dust shall be dust-proof, with the degree of protection to IP65.

Sealing gaskets shall be of neoprene rubber not less than 1.6mm thick.





Outdoor equipment shall be protected against direct sunlight and rain by installation inside an IP65

enclosure or under a canopy. uPVC materials which changes properties under sunlight shall not be used.

2.5.3 Accessories

2.5.3.1 Locks Where integral locks are specified, chromium plated brass cylinder locks shall be provided with engraved

labels. A minimum of two sets of keys shall be provided for each lock.

2.5.3.2 Labels Individual labels shall be supplied for each equipment item, and for each of the components of custom

assembled equipment, including relays, instruments, fuses, indication lamps, pushbuttons, selectors and

switches. A schedule of labels shall be prepared conforming to the Employer’s assets coding system and

shall be submitted to the Engineer for review before engraving is carried out. Where more than one set

of similar equipment or components are supplied, labels shall identify the separate function of each.

Labels for panels, cubicles and components shall be of laminated plastic (Trafalite) with engraved legends

or of clear Perspex with back-filled legends. Labels shall have black letters on a white background.

Danger and warning labels shall have a red background with white lettering. Character height shall be 1.5

times to that of width and shall be 3mm minimum for components. Labels shall be attached with stainless

steel drive screws. Adhesives are not permitted.

2.6 CABLING AND WIRING

2.6.1 Design 2.6.1.1 All cabling and wiring shall be neatly run. They shall be completely enclosed in conduit,

boards; or mounted on cable tray as specified.

2.6.1.2 All auxiliary circuit wiring inside the boards shall be not less than 1.5mm². Wiring from the

fixed part of the panel to the movable part, such as hinged door, shall be enclosed by flexible

LSOH tubing. They shall, wherever possible, be grouped and laced together in a neat

manner. Different insulation colours shall be provided to distinguish the various circuits. All

wires shall also have at both ends a coded ferrule of insulating materials permanently marked

with suitable characters and codes. Each connection shall terminate at an approved type of

terminal block, which shall also be suitably labelled. Connectors or soldered joints are not

permitted in the auxiliary circuit wiring. Exposed live terminals shall be suitably shrouded or

covered.

2.6.1.3 Each cable shall be clearly and permanently tagged at each end with cable number,

destination code and terminal identification of the device involved. This cable number and

destination code shall correspond to the respective cable numbers and device identification

shown on the schematic diagrams. Colour coding requirements of the relevant SANS

specifications (or BS) shall be adhered to.





2.6.2 Terminal Blocks 2.6.2.1 Terminal blocks for power and control wiring shall be of moulded anti-tracking type, clipped

onto common brackets. Single terminal shall be replaceable without dismounting adjacent

terminals.

2.6.2.2 Terminal blocks shall be designed to securely clamp the wire between two plates secured by

a captive screw. Pinch screw type terminal blocks will not be accepted.

2.6.2.3 Cables having the same number (same phase notation) shall be terminated at adjacent

terminals and connected by means of cable jumpers at the terminal block. Terminals utilised

for relay and instrument circuits shall be equipped with jacks for connection of test leads.

2.6.2.4 Terminal blocks shall be grouped according to the working voltage, power circuits and control

circuits. Each group shall be segregated from the other groups, distinctively labelled and

provided with flame retardant transparent covers at the front.

2.6.2.5 Terminals which are still energized with mains supply off shall be shielded and indicated.

2.6.2.6 White ferrules shall be provided on each terminal for circuit identification, numbered

according to the wiring diagrams.

2.6.2.7 Approximately 20% spare terminals, and not less than two numbers, shall be provided on

each group of terminal block.

3. EARTHING AND BONDING

3.1 SCOPE

All metal works either associated with or not associated with an electrical installation but not forming part

of a live conductor, including exposed conductive parts and extraneous conductive parts under the

Contract or of other Project Contractors, shall be solidly and effectively bonded and earthed in

accordance with SANS10142 – The Wiring of Premises requirements. For the exposed conductive parts

and extraneous conductive parts of other Project Contractors, the Contractor shall provide all necessary

provisions, including conduits, earthing tapes/cables, etc, to the closest connection point to facilitate the

connection to earth by the other Project Contractors.

The earth electrodes of each main/clean earth mat shall be so spaced that their individual resistance

areas do not overlap. The earth mats shall be so spaced that the resistance areas of individual earth mats

do not overlap and shall be sited as far as possible from each other within the building footprint.

Two earthing conductors shall be bonded to different parts and routed differently from the major

equipment, including LV distribution boards, motor control centres, supply authority transformer earth,

power transformer and standby generator neutral to the main earthing terminal.

All the protective earth conductors shall be minimum 25mm x 3mm tinned copper tape.

Detailed arrangement, including the size, bonding location, routing and installation method, shall be

submitted for approval prior to commencement of the installation work.






Earthing and bonding requirements and materials shall comply with the latest version of the following

standards or equivalent national standards.

3.2.1.1 BS 1432 Copper for Electrical Purposes: High Conductivity Copper Rectangular Conductors

with Drawn or Rolled Edges

3.2.1.2 SANS 804 Unwrought tough pitch coppers: Electrolytic tough pitch high conductivity copper

3.2.1.3 BS 2872 Copper and Copper Alloys: Forging Stock and Forgings

3.2.1.4 SANS 1063 Earth Rods, Couplers and Connections

3.2.1.5 BS 7430 Codes of Practice for Earthing

3.2.1.6 SANS 10198-3 The selection, handling and installation of electric power cables of rating not

exceeding 33 kV Part 3: Earthing systems - General provisions

3.2.1.7 SANS 10198-12 The selection, handling and installation of electric power cables of rating not

exceeding 33 kV Part 12: Installation of earthing system

3.2.1.8 SANS 10199 The design and installation of earth electrodes

3.2.1.9 SANS 10292 Earthing of low-voltage (LV) distribution systems

3.2.1.10 SANS 10142 The wiring of premises - Part 1: Low voltage installations

3.2.1.11 ANSI/IEEE Std 80 IEEE Guide for Safety in AC Substation Grounding

3.2.1.12 NRS076 Earthing of distribution substations with nominal voltages up to and including 132 kV

3.2.1.13 IEEE 1100 Recommended Practice for Powering and Grounding of Sensitive Electronic

Equipment

3.2.1.14 SANS61024 Earthing of distribution substations with nominal voltages up to and including

132 kV

3.3 EARTHING MATS

Each earthing mat shall comprise not less than six copper earthing rods or copper tapes driven or buried

into the ground to a suitable depth. The actual number of earthing rods or copper tapes will be

determined by the Engineer, depending on the resistivity of the soil on site to achieve an earth resistance

of not greater than 0.5ohm for a single earth mat. A typical earthing mat at each station will be

constructed in accordance with the following description:

At 200mm below the base slab, 6 holes of 90mm diameter, 10m deep at locations A, B, C, D, E and F

shall be determined by the Engineer on Site for each earth mat.

A copper (annealed) tape of 40 x 4mm will be inserted into the full depth of each hole and an extra

length of 300mm is required at the top to allow for connections to be made.

A mixture of 60% bentonite and 40% of gypsum to 125% of water (by volume) mixed to give a thick

slurry will be grouted into the holes and then allowed to solidify. The grouting will not trap any air in the

holes.

The earth electrodes at A, B, C, D, E and F (i.e. the copper tapes in bentonite and gypsum) will be

interconnected by two stranded bare copper conductors 120mm² or its equivalent.





The connections will be brazed to achieve a good and reliable joint to withstand anticipated fault

currents. The copper conductors will be flattened and clamped to the copper tapes while brazing.

The earth electrodes of each main earth mat shall be interconnected below base slab level by two groups

of copper conductors. Each group of copper conductors shall be connected to a principal earth lead and

interconnected with each earth electrode such that one of the principal earth leads can be disconnected

for testing. The positions of principal earth leads in relation to the earth mat shall be chosen so as to

minimize differences in distance between individual electrodes and their nearest principal earth leads.

Two principal earth leads P1 and P2 each of 50mm x 10mm copper (annealed) tapes shall be provided

and connected to the earth electrodes by one stranded bare copper conductor 120mm² or its equivalent.

These principal earth leads shall be arranged to emerge through the finished floor screed in positions

clear from all reinforcement and to be agreed on Site.

The main earth mats shall be bonded to the reinforcement of the structure by brazed connection.

3.3.1 Main Earthing Terminal

3.3.1.1 A solid copper main earthing terminal of ample size shall be provided for every electrical

installation at a position near the main incoming switch or switchboard or MCC, which is fed

directly from the supply authority’s transformer/supply, for the connection of the circuit

protective conductors, the main equipotential bonding conductors and the earthing

conductors to create the equipotential zone. The main earthing terminal complete with

disconnecting link of 50 x 10mm copper bar shall be connected to the earth via an earthing

conductor to an earth electrode or a group of electrodes.

3.3.1.2 Where an installation distributes to a number of buildings or units, a separate main earthing

terminal shall be provided for each individual building or unit at the point of intake thereby

creating separate equipotential zone in each building or unit.

3.3.2 Test Link 3.3.2.1 A bolted copper test link shall be provided for connecting, and disconnecting the principal

earth leads form the earthing network.

3.3.3 Earthing and Protective Conductors 3.3.3.1 Conductor Material

3.3.3.2 Earthing conductors shall be tinned copper tapes. Aluminium conductors shall not be used as

earthing conductors.

3.3.3.3 Connection to Electrode

3.3.3.4 The earthing conductor shall be connected to the earth electrode(s) by means of approved

copper connector-clamps such that the connection can only be disconnected by means of a

tool.





The connection shall be contained within a concrete lined earth pit with a substantial removable cover to

ensure accessibility and maintainability.

3.3.3.5 Protective Conductors for Electrical Apparatus

3.3.3.6 All metal parts including pipework and cable trays, other than those forming parts of any

electrical circuit, shall be effectively connected in an Approved manner onto the earth

system.

3.3.3.7 All switch/distribution boards shall be earthed using an earth strip to the principal earth

network which shall also be used by other designated Contractors for earthing their

equipment as generally shown on the earthing arrangement drawing. All necessary earth

strips to join to the principal network shall be included.

3.3.3.8 Major electrical apparatus shall be connected to the earthing system by means of copper

protective conductors of the minimum size given in the following table:

Apparatus Minimum Conductor

Size (mm)

A 11 or 22/0.38 kV services transformer (Two protective conductors) 50 x 6

B Switchboard and motor control centres (To be earthed at both

ends)

50 x 6

C 400V generator neutral (Two protective conductors each run in

separate route)

50 x 6

D 400V generator casing and cable box 25 x 3

E 400V motor casing and cable box (50 kW or above) 25 x 3

F Distribution Boards 25 x 3

G Battery panels 25 x 3

H UPS neutral 25 x 3

I Crane rail 25 x 3

J Reefer kiosks 25 x 3

K RTG power plug points 25 x 3

L High mast lights 25 x 3

M Power transformer 25 x 3

3.3.4 Main Equipotential Bonding Conductor

3.3.4.1 Conductor Material Unless otherwise specified, main equipotential bonding conductors shall be of tinned copper. Aluminium

or copper clad aluminium conductors shall not be used for bonding connections to water pipes likely to be

subjected to condensation in normal use.





3.3.4.2 Bonding Position Main equipotential bonding conductors shall connect the extraneous conductive parts of other services

within the premises to the main earthing terminal of the installation. Such extraneous conductive parts

shall include main water and gas pipes, other service pipes and risers and exposed metallic parts of the

building structure liable to transmit a potential. Connections shall be made as near as practicable to the

point of entry of the non-electrical services into the premises concerned, and shall be on the installation

side of the possible breaks in the system, such as gas meter or water meter.

3.3.4.3 Bonding Method The main equipotential bonding conductors shall be securely and reliably connected to extraneous

conductive parts of the non-electrical services by means of a copper connector-clamp of an approved

type suitable for the particular applications. All contact surfaces shall be clean and free from non-

conducting materials, such as grease or paint, before the connector-clamp is installed.

3.3.5 Supplementary Bonding Conductor

3.3.5.1 Conductor Material Unless otherwise specified, supplementary bonding conductors shall be of tinned copper. Aluminium or

copper clad aluminium conductor shall not be used for bonding connections to water pipes likely to be

subjected to condensation in normal use.

3.3.5.2 Bonding Method 3.3.5.3 The supplementary bonding conductors shall be solidly and effectively connected to the

extraneous or exposed conductive parts by means of a tinned copper connector-clamp of an

approved type suitable for the application. All contact surfaces shall be clean and free from

non-conducting materials, such as grease or paint, before the connector-clamp is installed.

3.3.5.4 For surface conduit installations, the supplementary bonding conductor shall be terminated at

the nearest conduit for conduit box forming an integral part of the conduit installation.

3.3.5.5 For concealed conduit installations, the supplementary bonding conductors shall be

terminated at a tinned copper earth terminal fitted inside a BS4662 metal box forming an

integral part of the conduit installation. The BS4662 metal conduit box shall be located as

near as possible to the bonding position and the exposed part of the supplementary bonding

conductor shall be made as short as possible.

3.3.6 Earthing Conductor

3.3.6.1 General Earthing conductors may be formed by a separate conductor/cable, the metallic sheath or armour of a

cable, part of the same cable as the associated live conductor, rigid steel conduits, trunking or ducting, or

the metal enclosure of the wiring system. Flexible conduits and the exposed conductive parts of

equipment shall not form part of the circuit protective conductors.





3.3.6.2 Earthing conductors for Socket Outlet For every socket outlet, a separate circuit protective conductor shall be provided connecting the earth

terminal of the socket outlet and that inside the enclosure accommodating the socket outlet.

3.3.6.3 Earthing conductors for Flexible Conduit For every length of flexible conduit, a separate circuit protective conductor shall be provided inside the

conduit to ensure the earth continuity of the installation between the two ends of the flexible conduit.

3.3.6.4 Earthing conductors for Busbar Trunking and Busway

A tinned copper tape of minimum 25 x 3mm in cross section shall be provided for the entire length of a

busbar trunking or busway. The tinned copper tape shall be bonded to the busbar trunking or busway at

intervals not exceeding 3 m and at the position of each tap-off point.

Subject to review by the Engineer, the provision of tinned copper tapes for a busbar trunking or busway

may be exempted provided that the enclosure of the busbar trunking or busway can be proved to satisfy

the full requirements of the circuit protective conductor.

3.3.6.5 Earthing conductors for Final Ring Circuit

The circuit protective conductor of every ring final circuit shall also be run in the form of a ring having

both ends connected to the earth terminal at the origin of the circuit.

3.3.7 Fixing Accessories 3.3.7.1 Tape clips for earthing tapes shall be of the direct contact type with two fixing screws flush

with the clamp surface and manufactured from tinned copper or naval brass complying with

the requirement of BS2872 designation CZ 112.

3.3.7.2 Earth rod to tape clamps shall be of heavy duty type with one fixing screw pressing the rod

and tape against the clamp body manufactured from tinned copper or naval brass.

3.3.7.3 Disconnecting link of 50 x 6mm tinned copper bar shall be provided complete with channel

base and insulator studs and nuts.

3.3.7.4 Square junction tape clamps shall be manufactured from tinned copper or high conducting

copper alloy with 4 fixing screws flush with the clamp surface suitable for making straight

joints, tee joints or cross joints between copper tapes.

3.3.8 Earthing Cable Colour Identification

All cables used as protective conductors, including earthing conductors, main equipotential bonding

conductors, supplementary bonding conductors and circuit protective conductors shall be identified by the

colour combination "green and yellow" as per SANS10142, clause 6.3.3.2. Such colour combination shall

not be used for other identification purposes.





4. LIGHTNING PROTECTION SYSTEM

4.1 SCOPE

A lightning protection system shall be provided to protect the following.

4.1.1.1 Above-ground structures from a direct lightning strike.

4.1.1.2 The equipment located within the zone of protection.

4.1.1.3 Personnel working within the zone of protection.

A lightning protection system shall be installed at all ancillary buildings and structures unless otherwise

specified.


The lightning system and accessories shall comply with the relevant latest version of the following

standards or equivalent national standards.

4.2.1.1 BS6651 Code of Practice for Protection of Structures against Lightning

4.2.1.2 SANS10313 The protection of structures against lightning

4.2.1.3 BS7430 Code of Practice for Earthing

4.2.1.4 SANS10292 Earthing of low-voltage (LV) distribution systems

4.2.1.5 BS7671 Requirements for Electrical Installations

4.3 SYSTEM REQUIREMENTS

4.3.1.1 The lightning protection system shall convey lightning discharges to ground without

electrification of the structure. It shall be designed in accordance with the recommendations

of SANS10313 or BS6651.

4.3.1.2 The complete lightning protection system shall consist of a network of air terminals at roof

level, interconnected by horizontal tapes. The whole air-termination system shall be

connected to down conductors which shall preferably run outside of the building. The down

conductors shall be bonded to a number of dedicated earth electrodes which do not make

contact with any part of the structures or buildings. A bond should be mechanically and

electrically effective and protected from corrosion in and erosion by the operating

environment.

4.3.1.3 Any protrusion from the sides of a structure, which may obstruct the vertical path of the

down conductor, shall be sleeved to allow the down conductor to pass through.





4.4 CONSTRUCTION AND MATERIALS

4.4.1 Air Termination

4.4.1.1 An air termination shall consist of vertical conductors, horizontal conductors or a system of

vertical and horizontal conductors.

4.4.1.2 For a roof of larger horizontal dimensions, the outer perimeter and the flat roof shall be

covered by an air termination network mesh of approximately 10m × 20m, so that no part of

the roof shall be more than 5 m from the nearest horizontal conductor. All salient points of

the roof structure shall be incorporated in the air termination network. All metallic

projections, ducts, vent pipes, railings, gutters, etc., on or above the main surface of the roof

of the structure, shall be fixed to, and form part of, the air termination network. Horizontal

conductors shall be fixed to the roof structure at regular intervals of not more than 1m by

means of suitable spacer saddles.

4.4.1.3 Vertical conductors shall have overall length not less than 450mm and diameter of 12mm

rods made of hard-drawn or annealed copper,

4.4.1.4 Mounted on a gunmetal base plate.

4.4.1.5 Horizontal conductors shall be of 25 x 3mm annealed copper strips.

4.4.1.6 Down Conductor

4.4.1.7 Unless otherwise specified, down conductors shall be of 25 × 3mm strips made of LSOH

sheathed soft annealed high conductivity copper tapes.

4.4.1.8 Down conductors shall be fixed on the external walls at regular intervals of not exceeding 1

m apart by means of heavy gauge non-ferrous spacer saddles. They shall follow the most

possible direct path between the air termination and the earth termination. However, the

down conductor shall be properly positioned and/or protected to avoid hazards of touch

potential or potential difference and generally isolated from the main earth. Other than the

disconnection link between the main earth terminal and the lightning protection system,

equipotential bonding between lightning conductors and the main earth is allowed only at

locations where isolation/insulation of the lightning conductors cannot be practically achieved

to prevent side-flashing, e.g. at the metal roof.

4.4.1.9 The number of down conductors to be installed shall depend on the building base area or the

building perimeter. At least two down conductors shall be installed. The number of down

conductors shall be one for each 20m or part thereof of the perimeter at roof level or ground

level, whichever is the greater. For building over 20m high, one per 10m or part thereof shall

be provided.

4.4.1.10 Each down conductor shall be complete with test joint and connecting to an earth

termination.





4.4.1.11 LSOH sleeve from 2m above ground to the earth pit shall be provided for the down

conductor.

4.4.1.12 Joints in copper tapes shall be avoided wherever possible, if joints are inevitable the copper

tapes shall be tinned, wiped clean while hot, then riveted, and sweated using a non-corrosive

flux.

4.4.1.13 Down conductors shall not be bonded to adjacent metalwork.

4.4.1.14 The use of coaxial cables as down conductors shall not be allowed.

4.4.2 Test Joint 4.4.2.1 Test joints shall be of phosphor bronze, gunmetal or copper. They shall comprise a heavy

circular base, to which a heavy circular cover of the same material shall be bolted. The flat

copper conductor shall be overlapped and placed so that they are clamped between the

cover and the base by means of at least four screws or studs.

4.4.2.2 The test joints shall be positioned so that they shall not be tampered with by unauthorised

persons. In cases where this is not possible, the earth tape/rod connector clamp shall be

used as an alternative test point in place of the test joint.

4.4.3 Earth Termination

4.4.3.1 The earth electrodes shall be made of copper clad lower carbon steel rods, the steel having a

high tensile strength of approximately 600N/mm² grade 43A of BS4360. The copper shall be

of 99.9% pure electrolytic copper molecularly bonded to the steel core, and have a thickness

not less than 0.25mm.

4.4.3.2 The earth electrode couplings shall be made from silicone bronze alloy, grade CS 101 of

BS2874, or bronze alloy grade CA102 of BS2871.

4.4.3.3 The earthing clamp body shall be of silicon aluminium bronze construction, having a

phosphor bronze screw for securing the tape to the earth electrode.

4.4.3.4 The whole assembly shall have a strong resistance to corrosion.

4.4.3.5 Each earth termination shall have a resistance to earth not exceeding the product given by

10 ohms times the number of earth termination to be provided. The whole of the lightning

protective system shall have a combined resistance to earth not exceeding 10 ohms. Where it

is difficult, due to local conditions to obtain a value of less than 10 ohms by the sole use of

rod electrodes, alternative or additional methods, e.g. the installation of tape of plate

electrodes may be used subject to review by the Engineer.

4.4.4 Spacer Saddle 4.4.4.1 Spacer saddles shall be of high quality metal. For copper conductors, brass or gunmetal shall

be used. For aluminium conductors, pressing or casting aluminium alloys shall be used.

4.4.4.2 Non-metallic spacer saddles shall only be used when down conductors are provided with non-

metallic sheathing.





4.4.5 Connection to Earth Termination Down conductors and bonding conductors shall be connected to the earth electrode. Each connection

shall be separately clamped and shall be fitted with a warning notice.

4.4.6 Bonding to Other Services Lightning protection systems shall normally be kept segregated from the metalwork of other services.

Minimum isolation clearances as illustrated in SANS10313 or BS6651 shall be maintained.

4.4.7 Joint in Conductors 4.4.7.1 Joints in roof conductors and/or down conductors shall be made by double riveting or by

suitable tape clamps. When clamps are used, the tape clamps shall each be provided with at

least 4 screws or bolts. All such joints shall be tinned and shall have negligible resistance and

good mechanical strength.

4.4.7.2 Alternatively, connectors may be jointed together by means of exothermic or thermit welding utilizing the high temperature reaction of powdered copper oxide and aluminium, provided that the proper material and equipment are used in accordance with the manufacturer’s recommended process.

4.4.8 Testing

The Contractor shall carry out tests to demonstrate to the Engineer that the combined resistance to earth

of the earth electrodes is not greater than 10 ohms.

The complete lightning protection system shall be checked for correct installation methods including and

the fixing and mechanical strength of:

• air terminal

• connecting tapes

• down conductors

• test links

The earth terminations, joints and bonding throughout the system shall be thoroughly examined for

secure termination and welding.

An electrical continuity test shall be carried out on the whole system after completion of the work.

The method of testing the lightning protection system shall comply with BS7430.

5. ELECTROMAGNETIC COMPATIBILITY

5.1.1 Definition

Electromagnetic compatibility (EMC) is defined as the ability of an equipment or system to function

satisfactorily in its electromagnetic environment without introducing intolerable electromagnetic

disturbances to other equipment or systems within that environment.

5.1.2 Performance

This Section contains details of the minimum Electromagnetic Compatibility (EMC) requirements for this

Contract. The requirements cover EMC between equipment under this Contract





5.2 SCOPE

Equipment under this Contract which may cause electro-magnetic disturbance shall include but not be

limited to the following:

5.2.1 Luminaires

5.2.1.1 Substation lighting 5.2.1.2 Tunnel lighting 5.2.1.3 High mast lighting 5.2.1.4 Reefer gantry lighting 5.2.1.5 Emergency lighting 5.2.1.6 Illuminated signage

5.2.2 Motor operated equipment including

5.2.2.1 Air Conditioning Units, including but not limited to packaged AC units, unitary systems, fan coil units, etc

5.2.2.2 Air Handling Units, including PAU’s (Primary Air Unit), computer room air conditioning units, etc.

5.2.2.3 Fans 5.2.2.4 Pumps

5.2.3 Power Distribution

5.2.3.1 HV/LV switchgear 5.2.3.2 Transformers 5.2.3.3 Power Factors Correction Equipment 5.2.3.4 Harmonic Filters 5.2.3.5 Uninterruptible Power Supply 5.2.3.6 Centralised Battery System 5.2.3.7 Power and Distribution Cables

5.2.4 Control Systems/microprocessor based system

5.2.4.1 Status monitoring systems (e.g. sprinkler, pump, FM200 flooding, water level, smoke curtain)

5.2.4.2 Control panels (e.g. AFA, repeater panel, smoke curtain, fire shutter, ECS, etc) 5.2.4.3 Motor Control Centres 5.2.4.4 Sensors and/or Limit Switches 5.2.4.5 ELV Cables and Distribution

5.2.5 Third Party Equipment

The third party equipment / systems most likely to be affected shall include but not be limited to the

following:

5.2.5.1 Video display unit / monitor

5.2.5.2 Computer / microprocessor based systems

5.2.5.3 Communication systems including, but not limited to, telephones, mobile communication

equipment, radios, etc.

5.3 STANDARDS

A list of relevant standards shall include where appropriate, but not be limited to the following:





5.3.1.1 IEC TR 1000-2-5 Electromagnetic compatibility (EMC). Environment. Classification of

electromagnetic environments. Basic EMC publication

5.3.1.2 BS4727-1 Glossary of electro technical, power, telecommunication, electronic, lighting and

colour terms. Terms common to power, telecommunications and electronic. Electromagnetic

compatibility

5.3.1.3 SANS 60050(121) International Electro technical Vocabulary – Chapter 121:

Electromagnetism

5.3.1.4 SANS 61000 Electromagnetic compatibility (EMC)

5.3.1.5 EN 13309 Construction machinery. Electromagnetic compatibility of machines with internal

electrical power supply.

5.3.1.6 SANS 50091-2 Specification for Uninterruptible Power Systems (UPS) Part 2: EMC

Requirements

5.3.1.7 EN 50130-4 Alarm systems. Electromagnetic compatibility. Product family standard: Immunity

requirements for components of fire, intruder and social alarm systems

5.3.1.8 EN 50263 Electromagnetic compatibility (EMC). Product standard for measuring relays and

protection equipment

5.3.1.9 EN 50270 Electromagnetic compatibility. Electrical apparatus for the detection and

measurement of combustible gases, toxic gases or oxygen

5.3.1.10 EN 55011 Industrial, scientific, and medial (ISM) radio-frequency equipment - Radio

disturbance characteristics - Limits and methods of measurement

5.3.1.11 EN 55014 Limits and methods of measurement of radio disturbance characteristics of

electrical motor operated and thermal appliances for household and similar purposes, electric

tools and similar electrical apparatus


electrical lighting and similar equipment


industrial, scientific, medial (ISM) radio-frequency equipment.

5.3.1.14 SANS 61000 Electromagnetic compatibility (EMC)

5.3.1.15 PD 6582 Electromagnetic compatibility (EMC). Guide to generic EMC standards

5.3.1.16 89/336/EEC EU Directive on EMC

5.4 GENERAL REQUIREMENTS

5.4.1 Certification

All equipment supplied by the Contractor deemed to produce electromagnetic disturbance shall be tested

and certified to meet the specified minimum requirements to the satisfaction of the Engineer.





5.4.2 Interference Considerations

The Contractor shall take into account the following interference mechanisms in his design and take all

necessary measures to remove their impact on the operation of the terminal.

5.4.2.1 Radiated interference - The performance of equipment shall meet the specifications at their

installed locations under the radiated interference of radiating antennas and/or handheld

transceivers.

5.4.2.2 Induced interference - The Contractor shall ensure that any signal and control cables other

than power cables used by one system are properly screened, bonded and earthed to

prevent noise and electric shock from exceeding the levels of: -

5.4.2.3 Longitudinal voltage to earth (continuous) - 60V

5.4.2.4 Longitudinal voltage to earth (fault condition) - 430V

5.4.2.5 Psophometrically weighted transverse voltage; 1mV

5.4.2.6 Electrostatic discharge (ESD) – Any equipment which contains sensitive electronic

components and is likely to be handled or touched by persons shall be protected against

electrostatic discharge.

5.4.2.7 Equipment shall be tested to 8kV using air discharge or 6kV using contact discharge in

accordance with SANS 61000-4-2.

5.4.2.8 Conducted interference - Contractor shall submit information on magnitudes and duration of

a.c. fault currents, including line-to-line fault and line-to-earth fault throughout the 380/230V

power supply system to the Engineer for review without objection. As a minimum

requirement, the maximum levels of conducted EMI of the installation shall not exceed the

levels specified in SANS 61000-6-2.

5.4.2.9 Fast transient / burst – Equipment shall be tested to 2kV peak as defined in SANS 61000-4-4.

5.4.2.10 Surge – Equipment shall be tested to 2kV (common mode) / 1kV (differential mode) as

defined in SANS 61000-4-5.

5.4.3 Electromagnetic Interference (EMI)

5.4.3.1 The Contractor shall ensure that the EMI generated by the equipment under this Contract

does not adversely affect the sensitive electronic equipment installed adjacent to them. As a

minimum, the maximum emission levels of the equipment shall not exceed the levels

specified in SANS 61000-6-4.

5.4.3.2 Any sensitive electronic equipment supplied will operate in an environment with substantial

amount of radiated interference present. The equipment may be subjected to radiated

energy from handheld transceivers and other communications systems.

5.4.3.3 As a minimum, the immunity levels of equipment shall meet the requirements specified in

SANS 61000-6-2.





5.4.3.4 All lighting equipment with a primary function of generating and/or distributing light intended

for illumination purposes and connected to the low voltage electricity supply or battery

operation shall meet the emission requirements of European Standard EN 55015. The

specification provides minimum limits for lighting devices operating at frequencies higher

than 100Hz for the following:

• Disturbance voltages at the mains supply terminals in the range of 9 kHz to 30MHz;

• Radiated magnetic field interference in the range of 9 kHz to 30MHz.

5.4.3.5 Light Dimmers

Light dimmers incorporating regulation control (if any) shall meet the requirements for disturbance voltage on their input and out put in the frequency range of 48.5kHz to 30MHz using incandescent lamps to provide the correct load specified in the European Standard EN 55014.

5.4.4 Management

5.4.4.1 The Contractor shall nominate an EMC coordinator to coordinate all EMC matters. The EMC

coordinator shall be an experienced professional in the EMC field.

5.4.4.2 The Contractor shall interface, liase, co-ordinate and exchange EMC data with all Project

Contractors to ensure EMC integrity in the design stage, and to appropriately demonstrate

compatibility in the testing and commissioning stage of the project in conjunction with these

Project Contractors. The Contractor shall submit a copy of all EMC related information to the

Engineer for review.

5.4.4.3 The Contractor shall prepare and submit for review by the Engineer an EMC Management

Plan. The Plan shall:

• Define the EMC philosophy, activities, means of control for the design processes and EMC submissions, to be supplied to demonstrate compliance with the Specification;

• Identify a comprehensive list of specifications, standards, method statements and procedures to be submitted to the Engineer for review;

• Include an initial list of design documentation, test specifications and test reports with a single paragraph description of each document to indicate compliance with the Specification;

• Include a programme which shall identify the dates for EMC submissions;

• Include a definition and description of the process and methods used for verification and validation of the Works compliance with the required EMC parameters in all respects; and

• Designate a person as the point of contact to deal with EMC matters; and

• Provide details of the nominated person and any subsequent change of the nominated person for review without objection by the Engineer.





5.4.4.4 The contractor shall demonstrate that the equipment comply with the EMC requirements in

factory during the Factory Acceptance Test stage.

5.4.4.5 In the Testing and Commissioning phase of the project, the Contractor shall verify, in co-

operation with all Project Contractors, through testing on-site that their systems are

electromagnetically compatible. The concerned Contractors shall demonstrate that their

respective systems operate to the specification requirements in the design environment

where all the items of equipment as a whole are set to operate.

5.4.5 Submittals

The Contractor shall submit the following documents for review by the Engineer:

5.4.5.1 EMC Management Plan;

5.4.5.2 Design documentation;

5.4.5.3 Test specifications; and

5.4.5.4 Test reports / certificates.

The Contractor shall submit EMC Management Plan for the review without objection by the Engineer.

If the testing documentation is not satisfactory, the Contractor shall make arrangements for the Engineer

to witness the EMC tests in order to demonstrate compliance with the relevant requirements defined in

the Standard Specification.





1. SECTION C: PLANT AND MATERIAL

1. INTRODUCTION

All equipment and services shall comply with the mandatory requirements of the Occupational Health and

Safety Act 85 of 1993, as amended. Particular reference is made to the requirement of the preparation

and submission of a risk analysis before any Plant and Materials are delivered, off-loaded or erected on

Site. This is applicable to ALL Contractors, sub-contractors, suppliers and vendors.

The Contractor shall comply with the National Construction Regulations of 2003.

The equipment offered shall comply with the latest editions of the relevant South African Bureau of

Standards (SABS) / South African National Standards (SANS) or British Standards (BS) or International

Electro-technical Commission (IEC) for Scientific and Industrial Research Publications and Reports.

2. GENERAL WORKS DESCRIPTION

2.1.1.1 The MV cable reticulation is primarily buried in ground along designated cable servitudes, drawn through a pipe and chamber system or mounted on brackets along the tunnel leading into the 4 x 600 series substations.

2.1.1.2 The LV cable reticulation is primarily drawn through a pipe and chamber system.

2.1.1.3 Illumination of outdoor areas will, in general, be provided for by suitably located floodlights mounted on strategically located high masts, street lights along the road infrastructure and bulkhead Luminaires mounted on the reefer structures.

2.1.1.4 All electrical equipment, i.e. MV switch panels, distribution transformers, miniature substations, LV switchboards, control panels and lighting distribution panels will be individually earthed by separate earthing conductors, run in a ring arrangement, directly to the main earth grid.

2.1.1.5 Vastrap Aluminium plates shall be installed across all open cable ducts / voids within substations. The Contractor shall include for suitably sized apertures, where cables pass through such flooring. All such “cable cut-outs shall be fitted with 60mm high “kickplate surrounds” to protect the cables against any form of mechanical damage

2.1.1.6 All sleeves that are installed by the Contractor but are for future use by others, as detailed in this scope of work, shall be equipped with a nylon draw wire and sealed to prevent the ingress of water/dirt.





2.1.1.7 All precautions, such as the installation of shuttering, shall be taken so as to ensure that injury and damage due to subsidence will not occur during excavations. Due cognisance to be given when working adjacent to roads, railways, walls, sewers, drains, pipes, concrete bases or similar structures.

2.1.1.8 The Contractor shall be responsible for the backfilling, compacting and re-instatement to original ground level of all trenches excavated. The Contractor shall remedy any settlement of cable trenches within a reasonable period after backfilling.

2.1.1.9 The Contractor shall keep the area in which work is conducted both clean and tidy and shall undertake to maintain good house keeping principles. Contractor shall remove all rubble, empty cable drums, etc. from the working area on a regular on-going basis.

2.1.1.10 Cable off-cuts shall be stored separately in a secure area. The cable off-cuts and spare cable on the cable drums remain the property of the Employer.

2.1.1.11 The Contractor is to supply a detailed record during the progress of the Contract showing the "As Built" conditions of the electrical installation. Deviations from the Contract drawings of all buried cables/sleeves, manhole locations, are to be accurately shown. The “red lining” of the drawings shall be undertaken by the Contractor continuously during the course of installation.

2.1.1.12 The supply and installation of cable markers and cable protection slabs shall be in strict accordance with the Employer's Technical Specification H500200-0-000-E-SP-0023.

2.1.1.13 Supply, installation and connecting all terminations for wire and cable, as required.

2.1.1.14 Contractor shall supply and install 6, 35 KV / 11 KV XLPE/SWA/PVC cable, 600 V / 1 000 V PVC/SWA/PVC cable, and PVC black insulated earth wire on cable brackets, in trenches or in sleeves.

2.1.1.15 Contractor shall supply and install all incoming / outgoing terminations and joints to the Employer supplied 11 KV MV switchgear as part of the Works to distribute the MV reticulation to the various satellite substations.

2.1.1.16 Contractor shall supply and install all incoming / outgoing terminations and joints to the Employer supplied 11 KV / 400 V transformers and miniature substations as part of the Works to provide small power to general lighting, workshops, building electrical infrastructure and reefers, etc.

2.1.1.17 Fabrication and installation of all miscellaneous galvanised steel mounting brackets and hanger supports for indoor electrical Plant and Materials as required.

2.1.1.18 Supply, pulling, anchoring and correctly terminating 6, 35 KV/11 KV ac (MV) cable and wire as required.

2.1.1.19 Supply, pulling, anchoring and correctly terminating 600V/1000V ac (LV) cable and wire as required.

2.1.1.20 Touch-up painting and correction of any dents, burrs or other damage of electrical Plant and Materials installed by the Contractor.





2.1.1.21 Excavation, placing cable, supplying and placing protective covers/markers and backfill for direct buried cable.

2.1.1.22 Providing qualified labour and supervision for inspections, testing and pre-commissioning of the entire installation as installed by the Contractor. The Contractor shall include for functional testing of the completed installation.

2.1.1.23 Provision of temporary lighting to allow for safe working conditions.

2.1.1.24 The Contractor shall provide for his own radio communication Plant and Materials and hand held radios for site use. The Plant and Materials shall be of the type that utilises radio frequencies not requiring licensing in terms of the law. Employer Security can confiscate the Plant and Materials that do not meet with these requirements.

2.1.1.25 The Contractor shall compile “Handover Packs”. Each “Handover Pack” shall be issued per feeder circuit on each LV Main Distribution Boards (MDB), inclusive of any LV Sub-Distribution Board and sub-circuits downstream of this feeder circuit.

Please note that Transnet Capital Projects has a responsibility to ensure that only client’s

recommended or preferred items of plant are procured from the nominated/recommended

manufacturers/suppliers. It is therefore imperative on the part of the Contractor to liase

with or contact the project electrical engineer in this regard before submitting tender prices

or prior to the procurement of any electrical equipment.

3. HARBOUR MAIN INTAKE SUBSTATION

Refer to the following drawings/ cable schedules:

3.1.1.1 H500206-1-433-E-CS-0001-01-JV : 11kV Switchboard 433-SGM-01 Cable Schedules 3.1.1.2 H500206-1-433-E-CS-0003-01-JV : 800kVA Mini Substation 433-MSS-02 Cable Schedules 3.1.1.3 H500206-1-433-E-GA-0001-01-JV : Existing 11kV Switchboard A General Arrangement 3.1.1.4 H500206-1-433-E-GA-0002-01-JV : Existing 11kV Switchboard B General Arrangement 3.1.1.5 H500206-1-433-E-GA-0003- 01-JV : Existing 400V Main Distribution Board A General

Arrangement 3.1.1.6 H500206-1-433-E-GA-0004-01-JV : Existing 400V Main Distribution Board B General

Arrangement 3.1.1.7 H500206-1-433-E-LA-0001-01-JV : Proposed Harbour Main Substation Layout 3.1.1.8 H500206-1-433-E-SL-0001-01-JV : Proposed Harbour Main 11kV S/S Single Line Diagram 3.1.1.9 H500206-1-433-E-SL-0002-01-JV : 400V Switchboard N0 433-MDB-01 Single Line Diagram 3.1.1.10 H500206-1-433-E-SL-0004-01-JV : 11Kv Miniature Sub Station 433-MSS-002 Single Line

Diagram 3.1.1.11 H500206-1-413-E-BD-0001-01-JV Proposed 11KV Reticulation Block Diagram This refurbished 11 KV substation is to be provided in the Works to provide 11 KV power supplies to the

substations in the port as the main feed from Eskom. It is to provide a 400 V power supply to the high

mast lighting and other local loads.

The existing transformer room, CO2 room and PFC A and PFC B room will be combined to create one

new room by others for the MV switchgear panels to be installed by ABB. The process will be staged in





order to remove the existing equipment before any structural changes to transform the existing layout to

the new one can commence.

3.2 Install and Commission new miniature substation MSS – 433 - 02

3.2.1.1 Dig new cable trench from the new MSS 2 plinth to the substation through switch room B.

3.2.1.2 Supply, deliver and lay in the trench new 1 x 100m x 3-core x 120mm² XLPE 6.35 /11 kV

cable for the new miniature substation MSS-433-02.

3.2.1.3 Supply, deliver and lay in the trench new 1 x 100m x 1-core x 120mm² PVC insulated

copper stranded earthing cable (11 kV side) for the new miniature substation MSS-433-02.

3.2.1.4 Supply and deliver new 800 kVA, 11.75/0.4 kV miniature substation MSS-433-02. This will be

free issue item under this contract.

3.2.1.5 Terminate one end of the above MV cables on HV side of the new miniature substation MSS-

433-02 and the 11 kV breaker on new 11 kV switchboard.

3.2.1.6 Supply and install 500mm x 50mm x 10mm copper earth bar for the new miniature

substation MSS-433-02.

3.2.1.7 Supply and install earth electrode for the new minisub.

3.2.1.8 Terminate one end of the above 1-core x 120mm² PVC insulated copper stranded earthing

cable (11 kV side) cable on earth bar of the new miniature substation MSS-433-02 and the

other end on the earth bar on new 11 kV switchboard.

3.2.1.9 Supply and install 1600 A mccb bus coupler complete with automatic changeover system 3.2.1.10 Test and cold commission the above installation

3.2.2 Decommission Existing 11kV Switchboard A

3.2.2.1 Swing Eskom incomers 1 and 2 from the old 11.75kV switchboard A to the new switchboard 3.2.2.2 Disconnect, cut and join the existing feeder cables to the new 150 mm² cables 3.2.2.3 Decommission the board 3.2.2.4 Transport to the designated storage location within the port.

3.2.3 Decommission Existing 11kV Switchboard B

3.2.3.1 Swing Eskom incomers 3 and 4 from the old 11.75kV switchboard B to the new switchboard 3.2.3.2 Disconnect, cut and join the existing feeder cables to the new 150 mm² cables 3.2.3.3 Decommission the board 3.2.3.4 Transport to the designated storage location within the port.

3.2.4 New 11 kV switchboard 433-SGM-01

The new board will be supplied and installed by ABB. It will comprise of new 37 x 11.75kV switchgear

panels (including bus riser and earthing panel) consisting of 4 x Incomers, 1 x Bus Section, 2 x Power

Factor Correction Feeders, 2 x Transformer Feeders, 24 x Main Feeders, 2 x Radial Feeders.





3.2.4.1 Supply and install new 30 X 100m x 150mm² XLPE MV cables

3.2.4.2 Supply and install new 30 X 100m x 1-core x 120mm² PVC earth cables.

3.2.4.3 Join and terminate the above cables to the feeders disconnected from the existing switchboards A and B.

3.2.4.4 Terminate 501 and 502 substations 3-core x 240mm² XLPE MV feeders.

3.2.4.5 Terminate 600, 602, 603 and 604 substations 3-core x 150mm² XLPE MV feeders

3.2.4.6 Terminate 501 and 502 substations 1-core x 120mm² PVC earth cables.

3.2.4.7 Terminate 600, 602, 603 and 604 substations 1-core x 120mm² PVC earth cables.

3.2.5 Decommission Existing PFC 1

3.2.5.1 Disconnect the existing PFC 1 MV cable from the existing switchboard A and PFC side and decommission it.

3.2.5.2 Transport to the designated storage location within the port.

3.2.6 Decommission Existing PFC 2

3.2.6.1 Disconnect the existing PFC 2 MV cable from the existing switchboard B and PFC side and decommission it.

3.2.6.2 Transport to the designated storage location within the port. 3.2.7 Decommission Existing 400 V Battery Chargers

3.2.7.1 Disconnect and decommission the existing 400 V battery chargers A and B. 3.2.7.2 Transport to the designated storage location within the port.

3.2.8 New 400 V Battery Chargers

3.2.8.1 These will be supplied, installed and commissioned by switchgear manufacturers in the battery room.

3.2.9 New Patch panels

3.2.9.1 Terminate 501, 502, 600, 602, 603 and 604 substations fibre optic cables

4. ETHERNET COMMUNICATION –SCADA, METERING & PROTECTION

Refer to the following drawings:

4.1.1.1 H500206-1-433-E-LA-0010-JV Equipment installation battery limit layout diagram

4.1.2 Fibre optic pilot cable and terminations

4.1.2.1 Fibre optic cable the Contractor shall supply, deliver, install and terminate a new fiber optic communication cable (100 Mbit/sWAN Ethernet communication network) including patch panels within the seven substations and the EL&P building for scada, metering and cable differential protection. The entire length of fibre cable is included in this Scope of Works. The works shall be done according to NRS 061-2 or NRS 078-2.





The fibre optic cable shall be 24 core, single mode and shall comply with Eskom specification TSP0025 for fibre optic duct cable and shall be tested and accepted in accordance with procedure TPR0150. Fibre optic cable installation shall comply with the cable manufacturer’s specifications on maximum puling tension and cable bending radius.

4.1.2.2 HDPE conduit pipe The fibre optic cable is to be laid / drawn inside a Class 6, 32mm diameter, high-density polyethylene (HDPE) conduit pipe. The supply and laying of this HDPE pipe (including trenching) is to be done under this contract. The HDPE conduit pipe will have a blue colour and a 2mm wall thickness A type 2 polypropylene (PP) compression fitting with a 32mm diameter will be used to join and seal the HDPE conduit pipe. The compression fittings will consist of the following:

• Body - Black polypropylene • Nut – Black polypropylene • Gasket – Nitrilich rubber 70 shore • Clinching ring – Acetalich resin • Reinforcing ring – Stainless steel “AISI 430”

Draw pits shall be installed where the cable route changes direction. Compression joints are to be indicated on the as-built drawings.

4.1.2.3 Cabinets and patch panels The Contractor shall supply and install 19” cabinets each complete with the following equipment:

• 1 x 24 way patch panel complete with ST Mid couplers, ST pigtails and ST connectors and supplied and installed in accordance with Eskom specification TSP0236

• 1 x SEL 2505 unit • 2 x SEL 25060-4453X units

Cable glands are to be used where optic fibre cable enters the cabinets Fibre cables are to be routed in the 19” cabinet in accordance with Eskom specification TST41-115

Contractor must clarify all technical matters and queries related to the said communications network before submission of their tenders.





5. MV RETICULATION


5.1.1.1 H500206-1-266-E-SL-0006-JV Existing MV reticulation for the port of Cape Town Single Line Diagram

5.1.2 Harbour Main Intake Substation to 501 substation.

5.1.2.1 Supply and install new 2 x 3 core x 240mm² XLPE 6.35/11 kV copper cables from Harbour Main Intake substation to the new 501 substation for incomer number 1

5.1.2.2 Supply and install new 1 core x 120mm² PVC insulated copper stranded earth wire from Harbour Main Intake substation to the new 501 substation for incomer number 1



5.1.2.5 Terminate the cables in Harbour Main and 501 substations.

5.1.2.6 Test and commission the above installation.

5.1.3 Harbour Main Intake Substation to 502 substation.





5.1.3.5 Terminate the cables in Harbour Main and 502 substation.


Please note that this installation will involve digging and laying the cables in a trench from Harbour Main

and into ducts as the installation proceeds toward substations 501 and 502 as per the drawings above.

The cable route is approximately 1500m long.





5.1.4 Fibre optic cable

5.1.4.1 Supply and install new fibre optic cables from Harbour Main Intake substation to the new 501 substation

5.1.4.2 Supply and install new fibre optic cables from Harbour Main Intake substation to the new 502 substation

5.1.4.3 Supply and install new fibre optic cables from Harbour Main Intake substation to the refurbished 600 substation



5.1.4.6 Supply and install new fibre optic cables from Harbour Main Intake substation to the refurbished 604 substation.

5.1.4.7 Terminate the above installation into the patch panels in each respective substation.

6. Berth 501 Substation

This new 11 KV substation is to be provided in the Works to provide 11 KV power supplies to the reefer

miniature substations and to provide a 400 V power supply to the reefers, high mast lighting, RTGs

auxiliary power boxes and the other loads.


6.1.1.1 H500206-1-413-E-SL-0007-01-JV Proposed 501 11 k V switchgear single line diagram 6.1.1.2 H500206-1-413-E-LA-0005-01-JV Proposed Berth 501 Substation Layout 6.1.1.3 H500206-1-313-E-CS-0001-01-JV 11kV Switchboard 313-SGM-01 Cable Schedule 6.1.1.4 H500206-1-313-E-CS-0003-01-JV 400V Switchboard 313-MDB-01 Cable Schedule 6.1.1.5 H500206-1-313-E-GA-0001-01-JV 400V Switchgear No.313-MDB-01 General Arrangement 6.1.1.6 H500206-1-313-E-SL-0001-01-JV 400V Switchboard N0 313-MDB-01 Single Line Diagram 6.1.2 New 11 kV switchboard 313-SGM-01

The new board will be supplied and installed by ABB. It will consist of New 14 panel 11.75kV switchgear

made up of 2 x Incomers, 1 x Bus Section, 1 x Transformer Feeder, 8 x Radial (including bus riser and

earthing panel).

6.1.2.1 Supply and install 500 x 50 x 10 mm earth bar for the switchboard 6.1.2.2 Terminate all new 120mm² PVC 1-Core earth wires on the switchboard earth bar. 6.1.2.3 Supply and install new 1 x40m x 120mm² XLPE MV cables for Transformer 6.1.2.4 Supply and install new 1 x40m x 120mm² PVC, 1-core earthing cable for Transformer 6.1.2.5 Terminate the above XLPE cables to the transformer feeder breaker on the switchboards 6.1.2.6 Terminate Harbour Mains MV incomers 1 and 2 to the respective panels on the board 6.1.2.7 Test and commission the above installation. Note: The 11 kV switchboard will be tested and cold commissioned by ABB

6.1.3 New 1000 kVA, 11.75/0.4 kV Transformer 313- TRF-01

6.1.3.1 Install new 1000 kVA 11.75/0.400 kV Transformer number 1 (313-TRF-01) 6.1.3.2 Supply and install 500 x 50 x 10 mm earth bar for the transformer 6.1.3.3 Terminate the new 1 x40m x 120mm² PVC 1-Core earth wire on the Transformer earth bar. 6.1.3.4 Terminate the new 1 x40m x 120mm² XLPE, 4-core MV cable on the Transformer. 6.1.3.5 Test and commission the above installation.





6.1.4 New 400 V Main Distribution Board 313-MDB-01

6.1.4.1 Supply and install new 400 V main distribution board with withdrawable main breaker 6.1.4.2 Supply and install 1600 A mccb bus coupler complete with automatic changeover system 6.1.4.3 Supply and install 500 x 50 x 10 mm earth bar for the main board 6.1.4.4 Terminate all new 120mm² PVC 1-Core earth wires on the 400 V board earth bar. 6.1.4.5 Supply and install new 4 x50m x 4- core 240mm² PVC SWA PVC 600/1000 V cables for

Transformer 313-TRF-01 6.1.4.6 Supply and install new 4 x50m x 120mm² PVC, 1-core earthing cable for Transformer 313-

TRF-01 6.1.4.7 Supply, install and terminate 1 x 50m x 4- core 16mm² PVC SWA PVC 600/1000 V cable for

air conditioning unit 313-ACU-01 6.1.4.8 Supply and install 1 X 50m x 120mm² PVC, 1-core earthing cable for Air conditioning unit

313-ACU-01 6.1.4.9 Test and commission the above installation.

6.1.5 New 400 / 230 V lighting Distribution Board 313-LDB-01

6.1.5.1 Supply and install new 400 /230 V lighting distribution board complete with breakers and neutral terminal block.

6.1.5.2 Supply and install substation internal lighting switches, cables, pipes and Luminaires as indicated in the bill.

6.1.5.3 Supply and install switched socket outlets and the associated cables and pipes 6.1.5.4 Supply and install lighting cables, pipes and Luminaires for substation security or external

lighting 6.1.5.5 Test and commission the above installation.

6.1.6 New Patch panel

6.1.6.1 Supply and install 1 x Patch panel 6.1.6.2 Terminate fibre optic cables from Habour Main substation 6.1.6.3 Test and commission the above installation.

7. BERTH 502 SUBSTATION

This new 11 KV substation is to be provided in the Works to provide 11 KV power supplies to the reefer

miniature substations and to provide a 400 V power supply to the reefers, high mast lighting, RTGs

auxiliary power boxes and the other loads.


7.1.1.1 H500206-1-413-E-SL-0008-01-JV Proposed 502 11 k V switchgear single line diagram 7.1.1.2 H500206-1-313-E-CS-0002-01-JV 11kV Switchboard 313-SGM-02 Cable Schedule 7.1.1.3 H500206-1-313-E-CS-0004-01-JV 400V Switchboard 313-MDB-02 Cable Schedule

7.1.1.4 H500206-1-313-E-SL-0002-01-JV 400 V Main DB N0 313-MDB-02 Single Line Diagram 7.1.1.5 H500206-1-413-E-LA-0006-01-JV Proposed Berth 502 Substation Layout 7.1.1.6 H500206-1-313-E-GA-0002-01-JV 400V Switchgear No.313-MDB-02 General Arrangement 7.1.2 New 11 kV switchboard 313-SGM-02





The new board will be supplied and installed by ABB. It will consist of New 14 panel 11.75kV switchgear

made up of 2 x Incomers, 1 x Bus Section, 1 x Transformer Feeder, 8 x Radial, 1 x bus riser and 1 x

earthing panel.

7.1.2.1 Supply and install new 11 KV frames for mounting the new switchboards 7.1.2.2 Supply and install 500 x 50 x 10 mm earth bar for the switchboard 7.1.2.3 Terminate all new 120mm² PVC 1-Core earth wires on the switchboard earth bar. 7.1.2.4 Supply and install new 1 x40m x 120mm² XLPE MV cables for Transformer 7.1.2.5 Supply and install new 1 x40m x 120mm² PVC, 1-core earthing cable for Transformer 7.1.2.6 Terminate the above XLPE cables to the transformer feeder breaker on the switchboards 7.1.2.7 Terminate Harbour Mains MV incomers 1 and 2 to the respective panels on the board 7.1.2.8 Test and commission the above installation. Note: The 11 kV switchboard will be tested and cold commissioned by ABB

7.1.3 New 1000 kVA, 11.75/0.4 kV Transformer 313- TRF-02

7.1.3.1 Install new 1000 kVA 11.75/0.400 kV Transformer number 1 (313-TRF-02) 7.1.3.2 Supply and install 500 x 50 x 10 mm earth bar for the transformer 7.1.3.3 Terminate the new 1 x40m x 120mm² PVC 1-Core earth wire on the Transformer earth bar. 7.1.3.4 Terminate the new 1 x40m x 120mm² XLPE, 4-core MV cable on the Transformer. 7.1.3.5 Test and commission the above installation.


7.1.4.1 Supply and install new 400 V main distribution board with withdrawable main breaker 7.1.4.2 Supply and install 500 x 50 x 10 mm earth bar for the main board 7.1.4.3 Terminate all new 120mm² PVC 1-Core earth wires on the 400 V board earth bar. 7.1.4.4 Supply and install new 4 x50m x 4- core 240mm² PVC SWA PVC 600/1000 V cables for

Transformer 313-TRF-02 7.1.4.5 Supply and install new 4 x50m x 120mm² PVC, 1-core earthing cable for Transformer 313-

TRF-02 7.1.4.6 Supply, install and terminate 1 x 50m x 4- core 16mm² PVC SWA PVC 600/1000 V cable for

air conditioning unit 313-ACU-02 7.1.4.7 Supply and install 1 X 50m x 120mm² PVC, 1-core earthing cable for Air conditioning unit

313-ACU-02 7.1.4.8 Test and commission the above installation.



7.1.5.2 Supply and install substation internal lighting switches, cables, pipes and Luminaires as indicated in the bill.

7.1.5.3 Supply and install switched socket outlets and the associated cables and pipes 7.1.5.4 Supply and install lighting cables, pipes and Luminaires for substation security or external

lighting 7.1.5.5 Test and commission the above installation.


7.1.6.1 Supply and install 1 x Patch panel 7.1.6.2 Terminate fibre optic cables from Harbour Main substation 7.1.6.3 Test and commission the above installation.






This refurbished 11 KV substation is to be provided in the Works to provide 11 KV power supplies to the

STS cranes, future reefer miniature substations and to provide a 400 V power supply to the reefers, high

mast lighting, RTGs auxiliary power boxes and the other loads.


8.1.1.1 H500206-1-413-E-SL-0003-01-JV Proposed 600 11 k V switchgear single line diagram 8.1.1.2 H500206-1-413-E-LA-0001-01-JV Proposed Berth 600 Berth Sub Layout 8.1.1.3 H500206-1-333-E-CS-0001-01-JV 11kV Switchboard 333-SGM-01 Cable Schedule 8.1.1.4 H500206-1-333-E-CS-0002-01-JV 400V Switchboard 333-MDB-01 Cable Schedule 8.1.1.5 H500206-1-333-E-GA-0001-01-JV 400V Switchgear No.333-MDB-01 GENERAL

ARRANGEMENT 8.1.1.6 H500206-1-333-E-GA-0002-01-JV Existing 11kV Switchboard General Arrangement 8.1.1.7 H500206-1-333-E-GA-0003-01-JV Existing 400V Main Distribution Board General

Arrangement 8.1.1.8 H500206-1-333-E-SL-0001-01-JV 400V Switchboard N0 333-MDB-01 Single Line Diagram


The new board will be supplied and installed by ABB. It will consist of 11 new 11.75kV switchgear panels


earthing panel. There will be interfacing with the Liebherr cranes contractor as they decommission the

existing cranes and provide supply for the new 11 kV STS cranes.

8.1.2.1 Supply and install 500 x 50 x 10 mm earth bar for the switchboard 8.1.2.2 Terminate all new 120mm² PVC 1-Core earth wires on the switchboard earth bar. 8.1.2.3 Terminate MV XLPE cables to the transformers feeder breakers on the switchboards for T1

and T5 8.1.2.4 Terminate Harbour Mains MV incomers 1 and 2 to the respective panels on the board 8.1.2.5 Swing and connect 2 x STS cranes MV feeders to the new switchboard from the old board. 8.1.2.6 Test and commission the above installation. Note: The 11 kV switchboard will be tested and cold commissioned by ABB

8.1.3 Existing 800 kVA, 11.75/0.4 kV Transformers T2 and T5

8.1.3.1 Disconnect the existing MV cables from the 11 KV breaker and the HV side of transformers 8.1.3.2 Supply and install 2 X 500 x 50 x 10 mm earth bars for T2 and T5 transformers 8.1.3.3 Supply and install new 2 x 3-core x 50m x 120mm² XLPE MV cables for Transformers T2 and

T5 8.1.3.4 Supply and install new 2 x 50m x 120mm² PVC 1-Core earth wire for Transformers T2 and

T5 8.1.3.5 Terminate the new 2 x 50m x 120mm² PVC 1-Core earth wire on the Transformer earth

bars. 8.1.3.6 Terminate the new 2 x 50m x 120mm² XLPE, 4-core MV cable on the HV bushings of

Transformers. 8.1.3.7 Test and commission the above installation.






8.1.4.1 Supply and install new 400 V main distribution board with withdrawable main breakers. 8.1.4.2 Supply and install 1600 A mccb bus coupler complete with automatic changeover system 8.1.4.3 Supply and install 500 x 50 x 10 mm earth bar for the 400 V main board 8.1.4.4 Terminate all new 120mm² PVC 1-Core earth wires on the 400 V board earth bar. 8.1.4.5 Supply and install new 4 x50m x 4- core 240mm² PVC SWA PVC 600/1000 V cables for

Transformers T2 and T5 8.1.4.6 Supply and install new 4 x50m x 120mm² PVC, 1-core earthing cable for Transformers T2

and T5 8.1.4.7 Supply, install and terminate 1 x 50m x 4- core 16mm² PVC SWA PVC 600/1000 V cable for

the air conditioning unit 333-ACU-01 8.1.4.8 Supply and install 1 X 50m x 120mm² PVC, 1-core earthing cable for Air conditioning unit

333-ACU-01 8.1.4.9 Supply, install and terminate 1 x 50m x 4- core 16mm² PVC SWA PVC 600/1000 V cable for

the local lighting distribution board 333-LDB-01 8.1.4.10 Supply and install 1 X 50m x 120mm² PVC, 1-core earthing cable for the local lighting

distribution board 333-LDB-01 8.1.4.11 Supply, install and terminate 1 x 20m x 3- core 2.5mm² PVC SWA PVC 600/1000 V cable for

the photocell 8.1.4.12 Supply, install and terminate 1 x 60m x 7- core 2.5mm² PVC SWA PVC 600/1000 V cable for

security lighting 8.1.4.13 Test and commission the above installation.



8.1.5.2 Supply and install substation internal lighting switches, cables, pipes and Luminaires as indicated on the drawings and in the bill.

8.1.5.3 Supply and install switched socket outlets and the associated cables and pipes 8.1.5.4 Supply and install lighting pipes and Luminaires for substation security or external lighting 8.1.5.5 Test and commission the above installation.



8.1.7 Existing 11 kV Switchboard

8.1.7.1 Cut and decommission the existing transformer T1, MV feeder cables 8.1.7.2 Cut and disconnect the existing 2 x STS cranes feeders and any other feeder and swing it to

the new board 333-SGM-01 8.1.7.3 Decommission the board 8.1.7.4 Transport to the designated storage location within the port.

8.1.8 Existing Transformer T3

8.1.8.1 Cut all cables, disconnect and decommission the existing 800 kVA, 11.75/0.400 kV transformer.






8.1.9 Existing 400 V board

8.1.9.1 Swing the 400 V loads into the new board 333-MDB-001 8.1.9.2 Disconnect and decommission the existing 400 V board. 8.1.9.3 Transport decommissioned board to the designated storage location within the port.

8.1.10 Existing 400 V Battery Charger

8.1.10.1 Disconnect and decommission the existing 400 V battery charger. 8.1.10.2 Transport the charger to the designated storage location within the port.






9.1.1.1 H500206-1-413-E-SL-0004-01-JV Proposed 602 11 k V switchgear single line diagram 9.1.1.2 H500206-1-413-E-LA-0002-01-JV Proposed Berth 602 Substation Layout 9.1.1.3 H500206-1-343-E-CS-0001-01-JV 11kV Switchboard 343-SGM-01 Cable Schedules 9.1.1.4 H500206-1-343-E-CS-0002-01-JV 400V Switchboard 343-MDB-01 Cable Schedules 9.1.1.5 H500206-1-343-E-GA-0001-01-JV 400V Switchgear No.343-MDB-01 GENERAL


Arrangement 9.1.1.8 H500206-1-343-E-SL-0001-01-JV 400V Switchboard N0 343-MDB-01 Single Line Diagram 9.1.2 New 11 kV switchboard 343-SGM-01





9.1.2.1 Supply and install new 11 KV frames for mounting the new switchboards 9.1.2.2 Supply and install 500 x 50 x 10 mm earth bar for the switchboard 9.1.2.3 Terminate all new 120mm² PVC 1-Core earth wires on the switchboard earth bar. 9.1.2.4 Terminate MV XLPE cables to the transformers feeder breakers on the switchboards for T1







9.1.3.1 Disconnect the existing MV cables from the 11 KV panel breaker and the HV side of transformers

9.1.3.2 Supply and install 2 X 500 x 50 x 10 mm earth bars for T2 and T5 transformers 9.1.3.3 Supply and install new 2 x 3-core x 50m x 120mm² XLPE MV cables for Transformers T2 and








































10.1.1.1 H500206-1-413-E-SL-0005-01-JV Proposed 603 11 k V switchgear single line diagram 10.1.1.2 H500206-1-413-E-LA-0003-01-JV Proposed Berth 603 Substation Layout 10.1.1.3 H500206-1-353-E-CS-0001-01-JV 11kV Switchboard 353-SGM-01 Cable Schedule 10.1.1.4 H500206-1-353-E-CS-0002-01-JV 400V Switchboard 353-MDB-01 Cable Schedule 10.1.1.5 H500206-1-353-E-GA-0001-01-JV 400V Switchgear No.353-MDB-01 GENERAL


Arrangement 10.1.1.8 H500206-1-353-E-SL-0001-01-JV 400V Switchboard N0 353-MDB-01 Single Line Diagram 10.1.2 New 11 kV switchboard 353-SGM-01









10.1.2.1 Supply and install new 11 KV frames for mounting the new switchboards 10.1.2.2 Supply and install 500 x 50 x 10 mm earth bar for the switchboard 10.1.2.3 Terminate all new 120mm² PVC 1-Core earth wires on the switchboard earth bar. 10.1.2.4 Terminate MV XLPE cables to the transformers feeder breakers on the switchboards for T1





















10.1.5.3 Supply and install switched socket outlets and the associated cables and pipes 10.1.5.4 Supply and install lighting pipes and Luminaires for substation security or external lighting























11.1.1.1 H500206-1-413-E-SL-0006-01-JV Proposed 604 11 k V switchgear single line diagram 11.1.1.2 H500206-1-413-E-LA-0004-01-JV Proposed Berth 604 Substation Layout 11.1.1.3 H500206-1-363-E-CS-0001-01-JV 11kV Switchboard 363-SGM-01 Cable Schedule 11.1.1.4 H500206-1-363-E-CS-0002-01-JV 400V Switchboard 363-MDB-01 Cable Schedule 11.1.1.5 H500206-1-363-E-GA-0001-01-JV 400V Switchgear No.363-MDB-01 GENERAL


Arrangement 11.1.1.8 H500206-1-363-E-SL-0001-01-JV 400V Switchboard N0 363-MDB-01 Single Line Diagram










11.1.2.1 Supply and install new 11 KV frames for mounting the new switchboards 11.1.2.2 Supply and install 1600 A mccb bus coupler complete with automatic changeover system 11.1.2.3 Supply and install 500 x 50 x 10 mm earth bar for the switchboard 11.1.2.4 Terminate all new 120mm² PVC 1-Core earth wires on the switchboard earth bar. 11.1.2.5 Terminate MV XLPE cables to the transformers feeder breakers on the switchboards for T1
















the photocell





11.1.4.12 Supply, install and terminate 1 x 60m x 7- core 2.5mm² PVC SWA PVC 600/1000 V cable for security lighting







11.1.6.1 Supply and install 1 x Patch panel 11.1.6.2 Terminate fibre optic cables from Habour Main substation 11.1.6.3 Test and commission the above installation.








12. HIGH MASTS LIGHTING

Refer to the following drawings: 12.1.1.1 H500206-1-313-E-SL-0005-01-JV Typical High Mast 313-HML-001 Single Line Diagram 12.1.1.2 H500206-1-373-E-LA-0001-01-JV High Mast 373-HML-038 Site Layout 12.1.1.3 H500206-1-373-E-LA-0002-01-JV High Mast 373-HML-049 Site Layout 12.1.1.4 H500206-1-393-E-LA-0001-01-JV High Mast 393-HML-022 Site Layout 12.1.1.5 H500206-1-313-E-LA-0002-01-JV High Mast 313-HML-033 Site Layout 12.1.1.6 H500206-1-313-E-LA-0001-01-JV High Mast 313-HML-032 Site Layout 12.1.1.7 H500206-1-333-E-LA-0001-01-JV High Mast 333-HML-028 Site Layout 12.1.1.8 H500206-1-343-E-LA-0001-01-JV High Mast 343-HML-019 Site Layout 12.1.1.9 H500206-1-343-E-LA-0003-01-JV High Mast 343-HML-017 Site Layout 12.1.1.10 H500206-1-323-E-LA-0001-01-JV High Mast 323-HML-037 Site Layout 12.1.1.11 H500206-1-323-E-LA-0002-01-JV High Mast 323-HML-048 Site Layout





The existing high masts are each 30m high. New positions have been identified based on the simulation done by Beka. New cables from substations will be installed and terminated on the lighting boards on the masts as well as replacing the existing Luminaires with the new ones( 507 x 400 W and 39 x 1000 W HPS/T Luminaires)

Item Activity

1 Supply and install 4c x 70 mm² PVC SWA PVC 600/1000 V cable


3 Supply and install 1c x 120 mm² PVC insulated copper stranded earth wire

4 Lay the supplied LV power cables and earthing cables into the 160 mm diameter ducts as

indicated on the drawings

5 Supply and install 27 x 9 x 400 W HPS/T BekaProjectolux narrow beam floodlight Luminaires

Supply and install 22 x 12 x 400 W HPS/T BekaProjectolux narrow beam floodlight Luminaires

6 Supply and install 13 x 3 x 1000 W HPS/T BekaProjectolux narrow beam floodlight Luminaires

7 Terminate the supplied cables to the 400 V Main distribution boards in the substations and the

high mast lights distribution boards as indicated on the drawings

8 Install earth electrodes on the new high mast foundations

9 Test and commission the above installations

13. RTG POWER KIOSKS

Single standard moulded industrial, watertight, interlocked switched socket outlets, IP65 or better, 63

Amp, 400V, 5 pin (3 phase, neutral & earth), RTG cranes LV Supply Auxiliary Power Boxes, Ampco round

type A0612 sockets, or equivalent, mechanically interlocked with a circuit breaker /earth leakage

combination rated at 15-25 kA rupturing capacity complete with matching plug top, or approved

equivalent, mounted on RTG plinths.

Item Activity






5 Supply and install 24 x Low voltage RTG power plugs for 600 series substations

6 Terminate the supplied cables to the 400 V Main distribution boards in the substations and the

RTG power plug boxes as indicated on the drawings

7 Test and commission the above installation





14. REEFER RETICULATION

Refer to the following drawings / schedules:

14.1.1.1 H500206-1-313-E-SL-0011-01-JV Reefer Mini Subs Single Line Diagram 14.1.1.2 H500206-1-313-E-LA-0004-01-JV Reefer gantry layout 14.1.1.3 H500206-1-313-E-SL-0004-01-JV 400V Typical Reefer Kiosk Single Line Diagram

14.2 REEFER CONTAINER KIOSK

14.2.1.1 Custom design and compact construction, space-saving container socket with plastic flanges

and integrated circuit breaker, checked and approved by International Classifications

Association (ICA). Container socket with single –handed operation without external

mechanical components with one circuit breaker per outlet, thermal magnetic tripping,

consisting of six (6) 32 Amp rated current , 380/440V, 50Hz, 4 pin (3 phase & earth) and 15

kA short circuit breaking capacity.

14.2.1.2 Stainless steel housing featuring electrostatic powder coating with subsequent oven drying.

14.2.1.3 High protection class IP 67 with plastic bayonet caps with chains.

14.2.1.4 Offered and delivered in its 3-hour setting.

14.2.1.5 Cable gland to IP 68.

14.2.1.6 Rugged construction which allows for reliable permanent operation and low maintenance

costs.

14.2.1.7 Tested to the following standards

•••• ISO 1496-2:1996

•••• IEC 60529:2000

• CEE Publication 17/2

•••• IEC 60309:1999

14.2.1.8 switched socket outlets supported on Reefer structures.

14.3 BEKANOVA 70W HPS BULKHEAD LUMINAIRE

14.3.1.1 The Contractor shall supply and install BEKANova 70W HPS bulkhead Luminaires installed on the reefer structures, complete with lamps, fixed onto steelwork at designated locations.

14.3.1.2 Each individual bulkhead luminaire, will be fed from the designated minisub by means of a 4mm squared cable via a suitably sized Pratley “Kwik Lok” Cable Box with a Polycarbonate Transparent cover, the box will also be equipped with suitably sized brass terminal rail and “Kwikbloks” for terminating of conductors and earth connections as well as any reducers that may be necessary for the installation.

14.3.1.3 Each bulkhead will, in turn, be fed from the “Pratley Kwik Lok” box, by means of a 2.5mm² x 3 core silicone cabtyre cable, drawn through open ended stailnless steel conduit, together with suitably sized compression glands.

14.3.1.4 All Kwik Lok boxes shall be individually tagged with tie on ID tags as manufactured and supplied by Pratley.





Item Activity

1 Install 36 x 1000 kVA, 11.75/0.4 kV miniature substations

2 Supply and install 3c x 185 mm² XLPE SWA PVC 6.35/11 k V cables


4 Lay the supplied MV power cables and earthing cables into the 160 mm diameter ducts as


5 Terminate the supplied cables to the 400 V reefer kiosks and the 400 V feeder breakers on the

miniature substations as indicated on the drawings



8 Supply and install 114 x 4 x Low voltage reefer kiosks (456)


indicated

10 Test and commission the above installation

15. FIRE PROTECTION BARRIERS

The supply and installation of fire barriers, Pyrocoat or approved equivalent, on cable openings in walls, cable slots in substation floors and for wall penetrations shall be as follows: 15.1.1.1 Fire barriers shall be installed at every point where cables enter/exit a wall penetration,

15.1.1.2 All wall penetrations in buildings shall be fully packed with mineral wool and sealed with a

fire protective coating. The nominal dry thickness shall be 3mm (minimum 2mm),

15.1.1.3 Asbestos-based products are not permitted,

15.1.1.4 All wall penetrations and fire barriers shall be compacted with Grade 1/P Mineral Wool of

density 160kg/m3. Polyurethane-based sealing compounds shall NOT be used.

16. SUBSTATION NOTICES AND SAFETY SIGNS

These shall be in accordance with the following: 16.1.1.1 Co2 fire extinguishers according to SABS 1151 mounted against the wall on the inside of the

substations

16.1.1.2 Folder with a complete set of wiring diagrams

16.1.1.3 Standard log book

16.1.1.4 Test book





16.1.1.5 Cabinet with two or more drawers 850 x650x 500mm for storage of books and drawings

16.1.1.6 Spoornet type A first aid kit

16.1.1.7 One combination chair/ladder per substation

16.1.1.8 One switching key box per substation

16.1.1.9 Standard padlocks

16.1.1.10 Statutory warning signs and notices, as depicted in the “Bill of Quantities”, shall be

purchased directly from a specialist supplier, typically:

• Electrical Substation “5 in 1” Notice,

• Unauthorised Entrance Prohibited Notice,

• Electrical Shock Treatment Notice,

• Danger/Gevaar/Ingozi Notice.

16.1.1.11 Information signs shall be custom made as follows:

• Emergency Signs: Size of letters shall be 50mm x 50mm and 12mm thick. Sign shall

have white lettering on a red background, e.g.:

• Information Signs: Substation and Transformer Bay numbering. Size of letters shall be

50mm x 50mm and 12mm thick. Sign shall have black lettering on a white background,

e.g.:

17. GENERAL

The following general items are applicable to the above substations and are included in the Scope of

Work:

17.1.1.1 Design, supply and delivery to site of the above items. Installation of all equipment supplied

17.1.1.2 Underground copper earth mats below substations, miniature substations, high mast lighting structures and buildings, and connections to the copper tails of these earth mats.

17.1.1.3 Factory Acceptance Testing of all equipment supplied as specified in this Specification.

17.1.1.4 Site Acceptance Testing (Cold Commissioning) of all equipment supplied and installed as specified in this Contract.

IN THE EVENT OF FIRE PHONE (XXX) XXX

��

��

��





18. EXCLUSIONS

The following items are excluded from the Scope of Work for this Contract and will be the responsibility

of others:

18.1.1.1 Supply and installation of MV switchgear, Scada and metering systems.

18.1.1.2 Supply of Transformers and miniature substations.

18.1.1.3 Supply and installation of cables for ship to shore cranes

18.1.1.4 Supply and installation of crane rail earthing system

18.1.1.5 Hot commissioning, i.e. energising of the primary equipment and verification of on load

parameters.





1. SECTION D: INSPECTION AND TESTING

1. INTRODUCTION

The Contractor shall ensure that the system and its parts are fully tested before delivery and installation

and shall then perform a final test after commissioning but prior to handover.

The testing shall consist of original subsystem tests, followed by a factory acceptance test (FAT) at the

Contractor’ premises, finally culminating with the Site Acceptance Test (SAT) in which the system as a

whole is tested. The Contractor shall give Port of Cape Town notice in writing two weeks prior to any

formal testing.

2. FACTORY ACCEPTANCE TESTS

The factory Acceptance test may be performed on subsystems as well as on the entire system.

3. SIITE ACCEPTANCE TEST

The system SAT shall be performed on all equipment in the scope of supply. The equipment shall be

installed in the final location for its planned operation prior to performance of the SAT.

The System SAT shall be conducted after all the various elements of the system have been installed in

the field and have all successfully completed their individual Subsystem SAT’s. The System SAT shall be

performed with equipment in the locations in which they will eventually operate.

This test shall demonstrate that the overall design of the System meets the functional and performance

requirements of the Specification in the field.

4. FINAL SYSTEM ACCEPTANCE

Port of Cape Town will accept the system by means of a formal take-over certificate when:

• The System and all items of equipment have successfully completed all the specified tests.

• All failures, problems and reservations noted during the tests have been corrected to Port of

Cape Town’s satisfaction or a plan of corrective action has been agreed between Port of

Cape Town and the Contractor.





1. SECTION E: DELIVERY AND INSTALLATION

1. DELIVERY

All equipment shall be delivered to the Port of Cape Town’s offices. The Contractor shall be responsible

for all shipping and transport required to effect such delivery of the equipment to their factory for

integration and factory acceptance testing and then, on completion of the factory acceptance, for the

shipping to site.

2. STORAGE

The Port of Cape Town will check the quantity and condition of all equipment delivered to site. Intact

delivery is required and any equipment damaged due to transportation shall not be accepted. Damaged

equipment shall not be repaired on site.

3. INSTALLATION

The master station hardware shall be installed in the Central Control Room after successful completion of

the FAT.





1. SECTION F: WARRANTY, SPARES, MAINTENANCE AND TRAINING

1. WARRANTY

The Contractor shall undertake to provide a warranty for a period of twelve months after handover of the

system to Port of Cape Town. The Contractor shall provide the following services as part of the warranty

support during this period:

• Repair or replace all faulty components damaged by normal operation or during first 12

months of operation.

• First line maintenance by competent Port of Cape Town personnel.

• Provide user support consisting of telephonic support of users who have successfully

attended the relevant training course. The Contractor shall regard the training courses as a

method of minimising their user support costs during this period. The response time for

user support requests shall be no longer than eight working hours.

2. SPARES

The Contractor shall provide a list of spares to be supplied within the scope of this project. The spares

holding shall take into account the probability of failure as well as the effect on the system should a spare

item not be available.

The Contractor shall also provide prices of spares with a guaranteed availability of ten years. The

Contractor shall include a completed schedule of the following format:

Item Description No of Items

in System

Offered

No of Spare

Items

Supplied

Unit Price

(For additional

purchases)

Lead time

(For additional

purchases)





3. MAINTENANCE

Port of Cape Town requires a system where maintenance can be performed on line as far as possible.

The maintenance requirement must be extremely low.

4. TRAINING

The Contractor shall provide training that shall be directly applicable to the actual equipment and

software to be provided as part of the system offered. Generalised training based upon roughly similar

equipment shall not be accepted.

The Contractor shall specify the following details of all courses included within the scope of the offer:

• Course Title

• Description of course content

• Duration of course

• Maximum number of attendees

• Prerequisites for attendees

• Location of course

The courses shall be run in a disciplined fashion to ensure that the Port of Cape Town personnel

who successfully complete the training courses shall be deemed to be competent.





1. SECTION G: ELECTRICAL DRAWINGS

Item Document Number Rev No.

Item Identificatio

n

Document Sub-Type

1 H500206 - 1-266 - E - SL - 0001 - 05 - JV 1 600 S/S 11KV existing SLD

Single Line Diagram

2 H500206 - 1-266 - E - SL - 0003 - 01 - JV B HM s/s 11KV existing SLD

Single Line Diagram

3 H500206 - 1-266 - E - SL - 0006 - 01 - JV B 11KV

Reticulation existing SLD

Single Line Diagram

4 H500206 - 1-313 - E - GA - 0001 - 01 - JV B

400V Switchgear

No.313-MDB-01

GENERAL ARRANGEMENT

5 H500206 - 1-313 - E - GA - 0002 - 01 - JV B

400V Switchgear

No.313-MDB-02

GENERAL ARRANGEMENT

6 H500206 - 1-313 - E - LA - 0001 - 01 - JV B High Mast

313-HML-032 Site Layout

LAYOUT



LAYOUT

8 H500206 - 1-313 - E - LA - 0003 - 01 - JV B RTG Power plug points

layout LAYOUT


layout LAYOUT


layout LAYOUT


layout LAYOUT

12 H500206 - 1-313 - E - LA - 0004 - 01 - JV B Reefer kiosk on gantry

layout LAYOUT

13 H500206 - 1-313 - E - SL - 0001 - 01 - JV B

400V Switchboard N0 313-MDB-

01

Single Line Diagram





14 H500206 - 1-313 - E - SL - 0001 - 02 - JV B


01

Single Line Diagram

15 H500206 - 1-313 - E - SL - 0001 - 03 - JV B


01

Single Line Diagram

16 H500206 - 1-313 - E - SL - 0002 - 01 - JV B


02

Single Line Diagram

17 H500206 - 1-313 - E - SL - 0002 - 02 - JV B


02

Single Line Diagram

18 H500206 - 1-313 - E - SL - 0002 - 03 - JV B


02

Single Line Diagram

19 H500206 - 1-313 - E - SL - 0003 - 01 - JV B 400V RTG Plug box

Single Line Diagram

20 H500206 - 1-313 - E - SL - 0004 - 01 - JV B 400V typical Reefer Kiosk

Single Line Diagram

21 H500206 - 1-313 - E - SL - 0005 - 01 - JV B 400V typical high mast lighting

Single Line Diagram

22 H500206 - 1-313 - E - SL - 0011 - 01 - JV B

11/0.4 KV Reefer

minisubs single lines

Single Line Diagram

23 H500206 - 1-313 - E - SL - 0012 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

24 H500206 - 1-313 - E - SL - 0013 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

25 H500206 - 1-313 - E - SL - 0014 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

26 H500206 - 1-313 - E - SL - 0015 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

27 H500206 - 1-313 - E - SL - 0016 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

28 H500206 - 1-313 - E - SL - 0017 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

29 H500206 - 1-313 - E - SL - 0018 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram





30 H500206 - 1-313 - E - SL - 0019 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

31 H500206 - 1-313 - E - SL - 0020 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

32 H500206 - 1-313 - E - SL - 0021 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

33 H500206 - 1-313 - E - SL - 0022 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

34 H500206 - 1-313 - E - SL - 0023 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

35 H500206 - 1-313 - E - SL - 0024 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

36 H500206 - 1-313 - E - SL - 0025 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

37 H500206 - 1-313 - E - SL - 0026 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

38 H500206 - 1-313 - E - SL - 0027 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

39 H500206 - 1-313 - E - SL - 0028 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

40 H500206 - 1-313 - E - SL - 0029 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

41 H500206 - 1-313 - E - SL - 0030 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

42 H500206 - 1-313 - E - SL - 0031 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

43 H500206 - 1-313 - E - SL - 0032 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

44 H500206 - 1-313 - E - SL - 0033 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

45 H500206 - 1-313 - E - SL - 0034 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram





46 H500206 - 1-313 - E - SL - 0035 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

47 H500206 - 1-313 - E - SL - 0036 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

48 H500206 - 1-313 - E - SL - 0037 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

49 H500206 - 1-313 - E - SL - 0038 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

50 H500206 - 1-313 - E - SL - 0039 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

51 H500206 - 1-313 - E - SL - 0040 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

52 H500206 - 1-313 - E - SL - 0041 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

53 H500206 - 1-313 - E - SL - 0042 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

54 H500206 - 1-313 - E - SL - 0043 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

55 H500206 - 1-313 - E - SL - 0044 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

56 H500206 - 1-313 - E - SL - 0045 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

57 H500206 - 1-313 - E - SL - 0046 - 01 - JV B

11/0.4 KV Reefer


Single Line Diagram

58 H500206 - 1-313 - E - SL - 0005 - 01 - JV 0 Typical High Mast 313-HML-001

Single Line Diagram



LAYOUT



LAYOUT

61 H500206 - 1-333 - E - GA - 0002 - 01 - JV B

Existing 11kV Switchboard

General Arrangement

GENERAL ARRANGEMENT





62 H500206 - 1-333 - E - GA - 0003 - 01 - JV B

Existing 400V Main

Distribution Board General Arrangement

GENERAL ARRANGEMENT



LAYOUT



LAYOUT

65 H500206 - 1-333 - E - SL - 0001 - 01 - JV B


01

Single Line Diagram

66 H500206 - 1-333 - E - SL - 0001 - 02 - JV B


01

Single Line Diagram

67 H500206 - 1-333 - E - SL - 0001 - 03 - JV B


01

Single Line Diagram

68 H500206 - 1-333 - E - SL - 0001 - 04 - JV B


01

Single Line Diagram

69 H500206 - 1-333 - E - SL - 0001 - 05 - JV B


01

Single Line Diagram

70 H500206 - 1-333 - E - SL - 0001 - 06 - JV B


01

Single Line Diagram

71 H500206 - 1-343 - E - GA - 0001 - 01 - JV B

400V Switchgear

No.343-MDB-01

GENERAL ARRANGEMENT

72 H500206 - 1-333 - E - SL - 0001 - 01 - JV B


01

Single Line Diagram

73 H500206 - 1-343 - E - GA - 0002 - 01 - JV B


General Arrangement

GENERAL ARRANGEMENT

74 H500206 - 1-343 - E - GA - 0003 - 01 - JV B

Existing 400V Main


GENERAL ARRANGEMENT

75 H500206 - 1-343 - E - SL - 0001 - 01 - JV B


01

Single Line Diagram

76 H500206 - 1-343 - E - SL - 0001 - 02 - JV B


01

Single Line Diagram

77 H500206 - 1-343 - E - SL - 0001 - 03 - JV B


01

Single Line Diagram





78 H500206 - 1-343 - E - SL - 0001 - 04 - JV B


01

Single Line Diagram

79 H500206 - 1-343 - E - SL - 0001 - 05 - JV B


01

Single Line Diagram

80 H500206 - 1-343 - E - SL - 0001 - 06 - JV B


01

Single Line Diagram

81 H500206 - 1-353 - E - GA - 0001 - 01 - JV B

400V Switchgear

No.353-MDB-01

GENERAL ARRANGEMENT

82 H500206 - 1-353 - E - GA - 0002 - 01 - JV B


General Arrangement

GENERAL ARRANGEMENT

83 H500206 - 1-353 - E - GA - 0003 - 01 - JV B

Existing 400V Main


GENERAL ARRANGEMENT

84 H500206 - 1-353 - E - SL - 0001 - 01 - JV B


01

Single Line Diagram

85 H500206 - 1-353 - E - SL - 0001 - 02 - JV B


01

Single Line Diagram

86 H500206 - 1-353 - E - SL - 0001 - 03 - JV B


01

Single Line Diagram

87 H500206 - 1-353 - E - SL - 0001 - 04 - JV B


01

Single Line Diagram

88 H500206 - 1-353 - E - SL - 0001 - 05 - JV B


01

Single Line Diagram

89 H500206 - 1-353 - E - SL - 0001 - 06 - JV B


01

Single Line Diagram

90 H500206 - 1-363 - E - GA - 0001 - 01 - JV B

400V Switchgear

No.363-MDB-01

GENERAL ARRANGEMENT

91 H500206 - 1-363 - E - GA - 0002 - 01 - JV B


General Arrangement

GENERAL ARRANGEMENT

92 H500206 - 1-363 - E - GA - 0003 - 01 - JV B

Existing 400V Main


GENERAL ARRANGEMENT

93 H500206 - 1-363 - E - SL - 0001 - 01 - JV B


01

Single Line Diagram





94 H500206 - 1-363 - E - SL - 0001 - 02 - JV B


01

Single Line Diagram

95 H500206 - 1-363 - E - SL - 0001 - 03 - JV B


01

Single Line Diagram

96 H500206 - 1-363 - E - SL - 0001 - 04 - JV B


01

Single Line Diagram

97 H500206 - 1-363 - E - SL - 0001 - 05 - JV B


01

Single Line Diagram

98 H500206 - 1-363 - E - SL - 0001 - 06 - JV B


01

Single Line Diagram



LAYOUT



LAYOUT



LAYOUT

102 H500206 - 1-413 - E - BD - 0001 - 01 - JV B Proposed

11KV Reticulation

Block Diagram

103 H500206 - 1-413 - E - LA - 0001 - 01 - JV B

Proposed 11/0.4kV 600 Substation

Layout

Layout

104 H500206 - 1-413 - E - LA - 0009 - 01 - JV B

11/0.4kV Miniature

Substations Layout

Layout

105 H500206 - 1-413 - E - LA - 0009 - 02 - JV C

11/0.4kV Miniature

Substations Layout

Layout

106 H500206 - 1-413 - E - LA - 0009 - 03 - JV C

11/0.4kV Miniature

Substations Layout

Layout

107 H500206 - 1-413 - E - SL - 0001 - 01 - JV B Existing MV Distribution

Network SLD

Single Line Diagram

108 H500206 - 1-413 - E - SL - 0002 - 01 - JV B Proposed MV Distribution

Network SLD

Single Line Diagram

109 H500206 - 1-413 - E - SL - 0003 - 01 - JV C

Proposed Berth 600

11kV Substation

Single Line Diagram





110 H500206 - 1-413 - E - SL - 0004 - 01 - JV C

Proposed Berth 602

11kV Substation

Single Line Diagram

111 H500206 - 1-413 - E - SL - 0005 - 01 - JV C

Proposed Berth 603

11kV Substation

Single Line Diagram

112 H500206 - 1-413 - E - SL - 0006 - 01 - JV C

Proposed Berth 604

11kV Substation

Single Line Diagram

113 H500206 - 1-413 - E - SL - 0007 - 01 - JV C

Proposed Berth 501

11kV Substation

Single Line Diagram

114 H500206 - 1-413 - E - SL - 0008 - 01 - JV B

Proposed Berth 502

11kV Substation

Single Line Diagram

114 H500206 - 1-413 - E - SL - 0011 - 01 - JV B Proposed MV Reticulation

Single Line Diagram

115 H500206 - 1-433 - E - GA - 0001 - 01 - JV 0 Existing 11kV Switchboard A

GENERAL ARRANGEMENT

116 H500206 - 1-433 - E - GA - 0002 - 01 - JV 0 Existing 11kV Switchboard B

GENERAL ARRANGEMENT

117 H500206 - 1-433 - E - GA - 0003 - 01 - JV 0

Existing 400V Main

Distribution Board A

GENERAL ARRANGEMENT

118 H500206 - 1-433 - E - GA - 0004 - 01 - JV 0

Existing 400V Main

Distribution Board B

GENERAL ARRANGEMENT

119 H500206 - 1-433 - E - LA - 0001 - 01 - JV B Proposed

Harbour Main Substation

LAYOUT

120 H500206 - 1-433 - E - LA - 0010 - 01 - JV B Proposed

Harbour Main Battery limit

LAYOUT

121 H500206 - 1-433 - E - SL - 0001 - 01 - JV B Proposed

Harbour Main 11kV S/S SLD

Single Line Diagram



Single Line Diagram



Single Line Diagram

124 H500206 - 1-433 - E - SL - 0002 - 01 - JV B


01

Single Line Diagram





125 H500206 - 1-433 - E - SL - 0003 - 01 - JV B

11Kv Miniature Sub Station 433-

MSS-001

Single Line Diagram

126 H500206 - 1-433 - E - SL - 0003 - 02 - JV B


MSS-002

Single Line Diagram

127 H500206 - 1-433 - E - SL - 0005 - 04 - JV B


MSS-001

Single Line Diagram