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GROUP CAPITAL DIVISION Majuba Rail Project Yard Optimisation Contract Technical Insert image here Mzayifani Mzebetshana and Team Date: 09 December 2015.

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Presentation on theme: "GROUP CAPITAL DIVISION Majuba Rail Project Yard Optimisation Contract Technical Insert image here Mzayifani Mzebetshana and Team Date: 09 December 2015."— Presentation transcript:

1 GROUP CAPITAL DIVISION Majuba Rail Project Yard Optimisation Contract Technical Insert image here Mzayifani Mzebetshana and Team Date: 09 December 2015

2 CONTENT/OUTLINE TECHNICAL Section 0: Summary/Overview/General All Sections Section 1: PWAY: Permanent Way (Perway) Section 2: OHTE: Overhead Track Equipment Section 3: SIG: Signalling Section 4: YL: Yard Lighting Section 5: SW: Storm Water Management Facilities Section 6: FAC: Facilities Section 7: TIP: Tippler Section 8: CON: Conveyor 2

3 LESSONS LEARNT WITH SIMILAR CONTRACTS DURING EVALUATIONS The Principal/Main Contractor does not issue the full and complete tender document to all of his sub-contractors The Principal/Main Contractor does not check that his sub-contractors portion of the tender document complies with the integrated and interface requirements of the total Works. The complexities associated with the interdependencies, interfaces and integration of this type of contract is not considered in an acceptable manner in the tender submissions. The non-compliance to qualifications/registrations/experience of key personnel. 3

4 ADDENDA TO WI WILL BE ISSUED The WI for Sections 1 (PWAY), 2 (OHTE) and 3 (YL) have been split between this contract and another contract to facilitate the progress of the rail yard works. The WI refers to battery limits that apply. Some of the Employers WI, drawings and BOQ’s (for information only) have been subsequently updated to reflect the Battery Limits Some Employers WI have been updated after further reviews Addenda reflecting the latest WI. Drawings, BOQ’s (for information only) will be issued. The tenderers takes note of such addenda and destroys any previous documents that are replaced by the Addendums. 4

5 EMPLOYER”S OBJECTIVE EMPLOYERS OBJECTIVE To achieve a throughput of 14Mtpa via the total coal delivery system (mines to rail to tippler to conveyor to stock yard) that is capable of handling the 14Mtpa burn-rate of the Majuba Power Station. The coal delivery system includes the new railway line (by Others) and the requirements of the rail yard and associated Works Information infrastructure/facilities, the tippler and the conveyor. The project comprises of different contracts to achieve the final operational railway line and this contract interfaces with those contracts to achieve the final coal delivery system. 5

6 PRICING INSTRUCTION The Lump Sum price is split into the items depicted the Pricing Instruction, Part C2: Pricing Data and totaled to the full lump sum price. Some of the items may be taken out and the lump sum price against an item in the pricing schedule is the full amount that will be taken out from the scope with no additional adjustment to the total Contract Price apart from the net value of the deduction. EMPLOYER’S BOQ The Employer’s BOQ’s (where applicable) are issued for information only and is not to be used for pricing purposes. The Contractor calculates the quantities based on the works information provided. 6

7 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS INTRODUCTION The works comprises eight distinct Sections as per the Content/ Outline slide Section 0: Summary/Overview/All Sections WI covers the requirements applicable to all sections of the contract as well as a very high level scope per section. The WI of the individual Sections 1 to 8 cover the particular requirements applicable to each Section. This is a design build lump sum contract The WI of the various Sections requires a range of design responsibilities ranging from full designs based on performance specifications up to and including limited and/or no designs. The Contractor takes cognisance of and manages the interfaces and interdependencies of all the Sections of the Contract throughout the project from inception through design, construction, commissioning, testing and handover. 7

8 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS TECHNICAL PROPOSAL/RETURNABLES The tenderer submits a Technical Proposal with his tender returnables as per the Invitation to Tender Document: “T2.1c- ‘List of Technical Tender Returnable Documents, Technical Proposal T2.1c-3. The tenderer submits a Technical Proposal for All Sections 0 to 8 as per the requirements of the Technical Returnable document which is in Annexure C SUM Technical returnables. The technical returnables is currently being revised and will be re- issued for use by the tenderers. It is important that the tenderers pay careful attention to the requirements and complies. The tenderer is evaluated based on the requirements of the Technical Proposal. 8

9 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS KEY/NON-KEY PERSONNEL Clause 2.7 “Contractor’s management, supervision and key people” refer. The tenderer submits the CV’s of key personnel as per the requirements of clauses 2.7.1 (Key Management and Construction Personnel) and 2.7.2 (Key Engineering Personnel). The tenderer provides CV’s for all non-key personnel that must have minimum qualifications in terms of statutory requirements. The tenderer provides organograms as per the Technical Proposal. 9

10 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS HOOK UP TO EXISTING (CLAUSE 5.1.20) The Power Station and the Rail Yard will be operational during the construction period. There is a yearly maintenance shut (i.e. planned outage) period of ten days during approximately July of each year. During the shut period the rail yard, tippler and conveyors up to the Assizing Complex (including the 4000t Silo) is out of service. Occupations/ outages/permit to work on or in close proximity to the “live” plant can be arranged with the Power Station as per the Generation Plant Safety Regulations 36-681 and the E7/2 for TFR. The Contractor shall be required to execute the Works in phases such that Works in areas that are clear of the “live” plant are prepared and ready for the tie-in into the existing plant. The tie-in into the existing plant and the dismantling/demolition/implosion the redundant plant shall be planned for during the yearly shut. 10

11 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS OCCUPATIONS/PERMIT TO WORK (CLAUSE 5.1.21) Annual Shut of approximately 10 days during approximately July of each year. Outages/Occupations Opportunities are available twice in a month (bi-weekly). 12 hours on a Tuesday (approximately second week of the month) and (12) hours on a Sunday (approximately last week of the month). As and when occupations subject to the prevailing operations of the plant in conjunction with the Supervisor. The Contractor arranges to train and certify a Responsible Person in terms of the Generation Plant Safety Regulations 36-681, who will be assessed and authorised by the Majuba Power Station. Majuba Power Station will provide an Authorised Person. The Contractor conforms to Site Regulation 36 Permission for Excavation and Backfilling (Excavation permits) 11

12 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS (Continued) Access to and the General Site of the Works 12

13 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS (Continued) The WI for Sections 1 (PWAY), 2 (OHTE) and 3 (YL) have been split between this contract and another contract to facilitate the progress of the rail yard works. The WI refers to battery limits that apply. 13

14 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS (Continued) CONTRACT DESIGN REQUIREMENTS The WI provided is based on the original Employer’s designs, for which the design responsibilities of the Contractor differ per Section from limited to full designs. The Contractor reviews the Employer’s designs issued with this tender and updates the designs where required in line with the provisions and requirements of clause 3.2 per Section and complies with all relevant Employer’s specifications/standards. The Employer’s BOQ’s are issued for information only and is not to be used for pricing purposes. The Contractor calculates the quantities based on the works information provided. Refer to clause 3.3: “Procedure for submission and acceptance of Contractor’s design” 14

15 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS (Continued) INTERFACES BETWEEN DIFFERENT PARTS OF THE CONTRACT The tenderer identifies/manages/implements the integration and interfacing between the various Sections of this contract and a few are mentioned below: The telecontrol system, dark fibres and MOD power/motor/heater supplies by SIG for OHTE. The step down points up to the with-drawable breakers by OHTE and the connection to it by SIG. Sleeves by PWAY for all Sections. The track slab/ stanchions by FAC for PWAY The power supplies and Control room by FAC for SIG Any others that may be overlooked and are evident in the WI. 15

16 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS (Continued) DRAWINGS All applicable general or layout Employers drawings for related Sections of the scope of work that are required for information and the successful execution of the Works are attached as Annexure A: SUM Schedule of Drawings. A schedule of drawings Annexure A: Section (1-8) Schedule of Drawings applicable to the various Sections is included per Section. 16

17 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS (Continued) SPECIFICATIONS AND RETURNABLES A schedule of General Specifications and Returnables, applicable to the Contract as a whole, is attached as Annexure B SUM Schedule of Specifications and Returnables. A schedule of specifications Annexure B: Section (1-8) Schedule of Specifications and Returnables applicable to the various Sections is included per Section. The Contractor submits a signed copy (or a separate letter/table) of each of the Annexure B (Sections 0-8) including any returnable Schedules therein with his tender indicating full compliance and or any non-compliances to all of the specifications therein. 17

18 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS (Continued) TESTING/COMMISSION/HAND-OVER General requirements for tests and inspections before delivery, commissioning, hand over and performance tests is discussed in the SUM WI and specifics per Section is discussed per Section. SPECIAL TOOLS AND SERVICING AIDS The Contractor supplies all special tools or servicing aids (mechanical type, laptops, software etc.) necessary for the efficient maintenance, repair or calibration of the equipment for all Sections of this contract. The tenderer submits a detailed list of the special tools or servicing aids. 18

19 SECTION 0: SUMMARY OVERVIEW/ GENERAL: ALL SECTIONS (Continued) TRAINING The Contractor provides for training requirements of all plant and schemes as may be required for all Sections of the Works. The training constitutes theoretical and practical training as may be required and includes a proposal of all training required per Section as per the SUM WI and any special requirements as per each Section required for the successful operation or maintenance of the installed Works The Contractor makes provision for all venues any catering or other requirements for the duration of the training. 19

20 SECTION 1: PWAY (Perway) PERWAY AND RAILWAY EARTHWORKS All perway, railway earthworks and associated works (drainage, culverts, level crossings, sleeve pipes) as per the Employer’s design drawings and specifications for the following: The installation of Set N15 into the existing NTG Spur line The extension of the NTG spur line. The new Maintenance Shed and Perway Stores lines from set N15 through set N16 toward the Shed and Store including all associated works. The re-positioning of set N14 and associated slewing/re-alignment of the tracks on the Palmford side. The replacement of the wooden sleepers on existing sets in the Yard with concrete sleepers suitable for the Yard Automation. Provision of two new stop blocks for the Maintenance Workshop Lines. 20

21 SECTION 1: PWAY (Perway) (Continued) ROADS AND ASSOCIATED EARTHWORKS All roads, earthworks and associated works (drainage, culverts, causeways, sleeve pipes) as per the Employer’s design drawings and specifications for the following: Alignment A Alignment B Alignment C & D Alignment E from ECC: 0.787598 (South) to ECC: 1.673067 (North) Alignment H and I from alignment E to ECC: 0.374011 21

22 SECTION 1: PWAY (Perway) (Continued) EXTENT OF THE DESIGN WORKS The tenderer calculates the quantities based on the works information provided. Liaise with Section 3 SIG and design the earthworks for the platforms which houses the local and tele control panels. Design the steps on the bank adjacent to Line 4 for access from the service road to the top of the bank. Liaise with all Sections of the Contract to ensure that all sleeve pipe crossing design requirements in the Railway/Roads environment are incorporated into the perway Works. All temporary Works, as may be required for the execution and completion of the Works. The Contractor relocates any services as needed. The Contractor shall protect any services that cross the new lines with the use of sleeves and half-sleeves as required. The Contractor notes the existing sub-surface D900mm water pipe line crossing at approximate chainage 68.920km that runs SE-NW at a depth unknown which is to be confirmed by the Contractor prior to construction commencement. 22

23 SECTION 1: PWAY (Perway) (Continued) PLANT AND MATERIALS PROVIDED AS “FREE ISSUE” The Employer provides the following materials new or used (released from the yard by another contractor) which will be stockpiled in the vicinity of the Majuba Rail Yard close to the Works: New 1:9 Left Hand 48kg Secantial Set N15 New 1:9 Right Hand 48kg Secantial Set N16 Used 48kg/m Rails in 12m lengths. Class B or better Used F4 Concrete sleepers. Class B or better Used Fist Pins. Class B or better 23

24 SECTION 2: OHTE OVERHEAD TRACK EQUIPMENT(OHTE): OHTE modifications associated with the repositioning of set (N14) and associated alignment Lines 5 and 6 on the Palmford side. OHTE associated with set N15 and the extension of the NTG spur. 11kV step down points: transformers with 11kV droppers, LV cables and withdrawable circuit breakers in a mast mounted enclosure. The supply and installation of the MOD at the hand operated track switch at location PS 67/160. The Supply and installation of motor operated track switch and section insulator at location PS70/579. The demolition of the existing track switches and section insulators and splicing through of the wires at mast location MY121. All bonding associated with this scope. Testing and commissioning of the installed equipment. 24

25 SECTION 2: OHTE (Continued) EXTENT OF THE DESIGN WORKS The tenderer calculates the quantities based on the works information provided The extension of the OHTE for the extended NTG spur. The Employer’s design depicts the use of a 162mm² ACSR catenary wire. The existing catenary wire is 80mm 2 copper. The Contractor reviews the Employer’s design at the splice points between the existing and the new wiring and update the design such that the catenaries are of the same material at the splice points. The Contractor measures the contact wire heights at all the interface points between the existing and the new Works as indicated on the drawings. The Contractor designs and implements all wiring gradient changes as required. Design of Stage works or Temporary works required to implement the Works. 25

26 26 SECTION 3: SIG (Signalling) EXISTING EMPLOYER’S DESIGN Signalling and Yard Automation Line Plan showing the entrance and exit signalling to the Yard as well as the Yard automation design (including yard sets to be automated) The interfacing between CTS, CAS Plant and apparatus installed by another contractor. Perway and Earthworks Layout drawing showing the location of the relay room, Admin & Control Tower depicting the proposed Signalling Power/Relay Room for the Entrance/Exit Yard Automation interlocking. Defined the Signalling Battery Limits. The Communication Fibre Route guidelines. Example of 2m x 2m Apparatus Room.

27 27 SECTION 3: SIG (Signalling) (Continued) EXTENT OF THE DESIGN WORKS The tenderer calculates the quantities based on the works information provided. The Contractor reviews the existing Employer’s designs and prepares a detailed design incorporating the minimum specifications including but not limited to the specific items listed below: The interface design changes to existing TFR layout 0.66/96321 to include changes to Entrance/Exit signalling to Majuba Yard as indicated on drawing No. 0.66/98067, which also shows the extent of the CTS contractor’s scope. The detailed design of alterations interfaces required for incorporating the new interlocking at Majuba relay room into the adjacent existing interlocking systems at Palmford, Majuba and Kabouter stations. The detailed design of the block communication between Majuba and Kabouter (Ermelo side) and between Majuba and Palmford is done using FSDT interface via fibre. The detail design for telecoms for the transfer of Dragging Equipment Detector data to the Majuba Control room

28 28 SECTION 3: SIG (Signalling) (Continued) EXTENT OF THE DESIGN WORKS (Continued) Detailed design for alterations and integration into the existing remote control system at the CTC centre at Ermelo and Standerton CTC. Palmford Station will be treated as a fringe station and will remain under Standerton CTC control. Detailed design for alterations and integration into the existing electrical Telecontrol at Empangeni and Standerton Control. The detailed design of yard automation system complete in terms of the scheme design. The design of the yard automation system includes all modes of control i.e. independent point control with a push button, local control panel and remote control. The detailed design of the cable route, communication link and interface between the existing weigh-bridge at the Tippler and the existing Tippler DCS.

29 29 SECTION 3: SIG (Signalling) (Continued) EXTENT OF THE DESIGN WORKS (Continued) The detail design of the Communication Fibre Route, and updating of drawing 0.66/96328 (guideline only) to incorporate the Majuba Yard requirements. The design and changes to existing TFR drawing CSE_7CS_722_SHT_1 showing the signalling modifications and changes required to Palmford Interlocking by the Contractor, as the layout of the yard on the Palmford side of the tippler was optimised to accommodate the full length of the train. The detailed design and supply of electrical power requirements at all step down points, all local control panels, all points machines, Communication system, telecontrol system and roclas as well as where there is no 11kV step down point.

30 30 SECTION 3: SIG (Signalling) (Continued) EXTENT OF THE DESIGN WORKS (Continued) The detail design, supply and installation of a suitably sized cable with earth wire from the 11kV step down point to the “Signalling Systems DB” as depicted in drawing 0.66/98382 (in Section 6: FAC), including the “Signalling Systems DB”, fully dressed and labelled to depict that the supply is from another source. The Contractor also designs for any other work arising from or incidental to the above or required from the Contractor for the successful completion of the Works, in accordance with the true meaning and intent of the Contract documents. Liaise with the Majuba Signalling CTS contractor who will be designing and building all Works related to the Kabouter station, Majuba relay room and supplying the new direct fibre optic link between Majuba and Palmford relay room.

31 31 SECTION 4: YL (Yard Lighting) EMPLOYER’S DESIGN The Employer has done a detailed design of the Yard Lighting System including the updated distribution, cabling and power supply requirements. All luminaires on the existing hinge masts and high masts must be replaced with LED luminaires The design lux level is 20 Lux. The Employer’s lighting design is based on BEKA Strada 400W HPS/T luminaires mounted on 20m hinged masts with spigots at a 150 inclination and BEKA Projectolux 1000W HPS/T floodlights for the existing high masts. The Employer did the lighting design to determine the extent of the mast positions, cabling and power supplies for the 20 lux design level. The Contractor uses the Employer’s design as depicted on the drawings for the new and existing hinged/high masts, distribution, cabling and power supplies.

32 32 SECTION 4: YL (Yard Lighting) (Continued) YL WORKS APPLICABLE TO THIS CONTRACT The design, supply and installation of the works as applicable to: All the high mast lights around the tippler area (JB24A, JB25A, JB28A, JB26A and JB27A) All the works along lines 5 and 6 (From JB1A and JB 2A up to and including JB30A) The works for JB65B and JB64B along the NTG extension including the feed from JB54B All the works along the new Maintenance lines (JB1D to JB8D) All the works associated with the Peripheral Lighting Design and Deliverables.

33 33 SECTION 4: YL (Yard Lighting) (Continued) FOR INFORMATION ONLY: YL PORTION OF THE WORKS BY ANOTHER CONTRACTOR All the works along the new CTS line and lines 1, 2, 3 and 4 of the yard (From JB69B up to and including JB30B just before the Tippler) All the works along the existing NTG spur (JB63B, JB62B, JB61B and JB60Bb) GENERAL WORKS REQUIRED Setting out of the Works. Supply and installation of luminaires on existing or new masts Supply and installation of double spigots on existing or new masts Supply and installation of single spigots on existing or new masts Design, supply and installation of 20m hinged masts

34 34 SECTION 4: YL (Yard Lighting) (Continued) GENERAL WORKS REQUIRED (Continued) Supply and installation of cables as depicted on the cable schedules. Supply and installation of luminaire power supplies at the masts Supply and installation/termination/connection of cables, wiring, junctions as required Modification of power supply feeding arrangements as required. Excavation and backfilling of cable trenches. Design, excavation and construction of foundations. Earthing of all new mast foundations and all other relevant lighting equipment. Spark-gap bonding of the lighting masts as per the Employer’s drawings.

35 35 SECTION 4: YL (Yard Lighting) (Continued) GENERAL WORKS REQUIRED (Continued) Testing and commissioning of the Yard Lighting system Decommissioning and disposal of redundant existing masts and associated equipment as depicted on the relevant drawings. Supply and installation of KKS numbering tags on masts, equipment and cables as required. Supply and installation of all signage and labelling in accordance with Eskom (ENGGEN04 Standard Coding Labelling For Majuba ) specifications Supply and installation of sleeve pipes. Liaise with Section 1 PWAY to determine which are supplied under their activities and works information and supply the rest that are not included therein and as required.

36 36 SECTION 4: YL (Yard Lighting) (Continued) GENERAL WORKS REQUIRED (Continued) Testing and commissioning of the Yard Lighting system including all associated equipment. The Contractor takes the as built lighting levels and provides a report to the Supervisor. Corrective actions must be provided if the as built lighting levels deviate from the design lighting levels

37 37 SECTION 4: YL (Yard Lighting) (Continued) EXTENT OF THE DESIGN WORKS The tenderer calculates the quantities based on the works information provided. Design of any Stage works or Temporary works required to implement the Works. Lighting Level, Hinged Masts, Foundations and Associated Design Responsibilities During the design, the Contractor takes cognisance of the “other” contractor’s design (portion that is excluded from this scope). The design is issued to the Contractor when it is completed by the other contractor. The Contractor uses the Employer’s fixed mast locations to simulate and attain a design lux level of 20 lux as per the Employer’s Cover Area drawing. The Contractor uses LED Luminaires for the hinged masts and high wattage or LED floodlights for the high masts during the simulation and supplies and installs the luminaires accordingly.

38 38 SECTION 4: YL (Yard Lighting) (Continued) EXTENT OF THE DESIGN WORKS (Continued) Lighting Level, Hinged Masts, Foundations and Associated Design Responsibilities (Continued) Refer to the LED Luminaire specification in clause 6.4. A detailed design of the new 20m hinged masts as required. Refer to Typical drawing no. SM-005-N-L2-D1-P0-R0 and the performance specification in clause 6.6 A suitable detailed design of the electrical connections per each type of new mast (1 or 2 luminaires) with full cognisance of the new connection/tap-off detail of the incoming and outgoing cables. A suitable detailed design for the upgrade of the existing electrical connection system from 1 luminaire to 2 luminaires with full cognisance of the existing connection/tap-off detail of the incoming and outgoing cables. A suitable detailed design for a three way incoming/outgoing cable connection as may be required at certain locations including cable pipe entry details

39 39 SECTION 4: YL (Yard Lighting) (Continued) EXTENT OF THE DESIGN WORKS (Continued) Lighting Level, Hinged Masts, Foundations and Associated Design Responsibilities (Continued) A detailed design of the new 20m mast pole foundations including cable pipe entry details. Refer to Typical drawing no. FD-100 and clause 6.5 Earthing and lightning protection for the mast/foundation combination An adapted mast base design for new masts where new masts may be required on existing foundations. Inspect and determine the quantities of existing masts that are in disrepair during the site visit and pre-tender submission. The Yard lighting masts, cabling, distribution and power supplies conforms to the relevant Eskom specifications. The foundation design considers the requirements of the Transnet Perway Maintenance Manual and other relevant specifications and standards such as and not limited to the E7/2.

40 40 SECTION 4: YL (Yard Lighting) (Continued) EXTENT OF THE DESIGN WORKS (Continued) Peripheral Lighting Design and Deliverables (Continued) The Employer requires lighting along the outermost railway lines (lines 1, 5 and 6) in addition to the Employer’s design. The lighting is required to light the shaded area adjacent to the Jumbo wagons due to the position of the hinged mast luminaires. The Contractor designs the lighting system and gets the acceptance from the Employer. The Contractor then provides a full scope of works including works information, drawings, and bills of quantities (priced). The Employer is considering the use of LED lighting on 2.3m poles. Refer to clause 3.2.3 for details Masts and Foundations in Disrepair Deliverable (Addendum) Some masts and foundations may be in disrepair and the Contractor inspects existing masts and foundations (condition assessment). The Contractor provides a full report and gets acceptance from the Employer. The Contractor provides a full scope of works including works information, drawings, and bills of quantities (priced).

41 41 SECTION 5: SW (Storm Water Repair) STORM WATER REPAIRS AT km 17 OF THE PALMFORD LINE Surveying and setting out of Works Construction of a 4 meter wide by 320 meter long temporary gravel access road and access ramp Clearing the route of the retaining wall of grass and har armor block stormwater drain lining to stockpile for subsequent use in re- instating the drain lining at the end of the concrete works. Excavation of foundations for the retaining wall situated along an operational railway Constructing a reinforced concrete retaining wall approximately 55 meters long Re-constructing a stormwater catch berm using rock fill, gabions and compacted earth material

42 42 SECTION 5: SW (Storm Water Repair) (Continued) EXTENT OF THE DESIGN WORKS The Employer has done detailed designs and the Contractor does the following: Concrete mix Access road and ramp Formwork Removal and re-instatement works for the har armor drain lining blocks Lateral support as necessary Traffic accommodation Dealing with water All other temporary works to ensure successful completion of the Works

43 43 SECTION 6: FAC (Facilities) HIGH LEVEL SCOPE In General: Investigations, Review of the Employer’s Design, Updating/Designing the Works based on the Employer’s requirements and the provision of all furniture and plant as stated in Clause 3.2 of the Works Information. Administration, Staff Facilities Building and Control Tower Surveying and setting out of works Construction of platform Excavation / Foundations Building services reticulation Earthing and lightning protection system Construction of building Commissioning and Handover

44 44 SECTION 6: FAC (Facilities) (Continued) HIGH LEVEL SCOPE (Continued) Associated Siteworks Carpark and related road works Carports Stormwater drainage Services reticulation (water, sewerage, stormwater drainage, electrical) Fencing 6.6k Reticulation The Contractor investigates the electrical network associated with the ring and does the load flow and fault studies and submits a study report to the Employer for review and acceptance. On-site Inspection, review and update the employers design for the building services 6.6kV reticulation: Reuse the existing 6.6kV panels (CSY board 3, panel 8 and CSY board 4, panel 7)

45 45 SECTION 6: FAC (Facilities) (Continued) HIGH LEVEL SCOPE (Continued) 6.6k Reticulation (Continued) Check the existing CT’s for compatibility, reuse/supply and install new, Convert the existing MCC protection into feeder protection on existing panels, Confirm feeder protection requirements with the Employer, Refurbish/Upgrade the existing panels as per the Contractor’s design, Investigate and implement the Majuba PS switching philosophy for the new 6.6kV building services network, Protection settings in conjunction with the Employer Supply and install all equipment required for the two feeder protection panels Design, supply and install two mini subs (315kVA) as per the Employer’s specification Perform earthing design including earthmat resistivity measurement Design, supply and install the reticulation system between the existing panels and the new mini subs. Commissioning and Handover

46 46 SECTION 6: FAC (Facilities) (Continued) EXTENT OF THE DESIGN WORKS The Employer has provided a design for the Facilities, however the Contractor shall review the Employer’s designs issued with this tender and update the designs where required in line with the provisions and requirements of clause 3.2 and complies with all relevant Employer’s specifications/standards. The BOQ’s are issued for information only and is not to be used for pricing purposes. The Contractor calculates the quantities based on the works information provided. The Contractor is bound by a combination of performance, functional and equipment specifications defined within the Works Information such that a complete functional system is provided. The Contractor shall obtain all statutory approvals for the Works from the Local Authorities as required.

47 47 SECTION 6: FAC (Facilities) (Continued) EXTENT OF THE DESIGN WORKS (Continued) The Contractor refers to the details of the design requirements in Clause 3.2 and includes the following is the high level summary: General: Temporary works and other Architectural: Optimise the Administration Building Ground Floor Layout Design and Other Furniture: For buildings Fire Protection Overhead Crane for the Diesel Depot Compressor for the Diesel Depot Fuel Storage and Dispensing Water Supply Sewage Pump Station at the Admin Building Sewer System to Replace the Septic Tank at the Diesel Locomotive Shed

48 48 SECTION 6: FAC (Facilities) (Continued) EXTENT OF THE DESIGN WORKS (Continued) The Contractor refers to the details of the design requirements in Clause 3.2 and includes the following is the high level summary (Continued): HVAC Systems Electrical Earthing and Lightning Protection MV (6.6kV nominal and rated at 11kV) Reticulation and Fault levels Mini-Substations: wound at 6.6kV/400V Various Others

49 49 COAL HANDLING PLANT – PROCESS OVERVIEW SECTION 7: TIP (Tippler)

50 50 COAL HANDLING PLANT – PROCESS OVERVIEW SECTION 7: TIP (Tippler)

51 UPGRADED COAL PLANT PROCESS

52 SECTION 7: TIP (Tippler) BATTERY LIMITS Tippler Belt feeder including discharge chute, skirting box assembly and dust suppression mechanisms feeding onto take out conveyors (top of take-out conveyor tail end) Complete Tippler plant excluding Perway rail Conveyor From the tail end of both the take-out conveyors up to and including the discharge point on the stacker including transfer chutes (top of take-out conveyor tail end to top of stacker tail end) From the tail end of both the take-out conveyors up to and including the extension of overland conveyor tail ends (top of take-out conveyor tail end to tail end of existing overland conveyors). 52

53 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Bulk Materials Handling Design, manufacture, supply, transport to site and install a new portal type indexer, Design, supply and installation of new train wagon holding devices, Modifications to the existing reclaim belt feeder system Replacement of hopper liners Supply and install new trunnion bearings and swivel blocks Inspection and realignment of gearboxes Inspection on the dumper motors 53

54 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Control and Instrumentation Control of the entire Tippler Plant is to be incorporated into the ABB DCS at the Tippler Control room. No 3 rd party or other controllers will be used Indexer and dumper enclosure, The replacement of all field instrumentation associated with the Tippler Plant, Logic and HMI changes to accommodate new Plant, equipment and functionality – to be compiled and tested offline prior to implementation, New cabling for all new equipment/instrumentation, Replacement of existing cabling and racking as and where required 54

55 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Control and Instrumentation (Continues) The replacement of all flexible festoon and energy chain cables, Supply fire detection in the Tippler area and interface to existing Ziton system, Supply of a Ziton HMI system for the tippler fire detection system, Supply of a public address system in the Tippler area and interface it to the existing system, Removal of the existing CCTV system in the Tippler area and supply a new IP based CCTV system along with a NVR and HMI) 55

56 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Low Pressure Service Design, supply and installation of a new dust suppression system (An Addendum will be provided during tender stage defining the performance parameters that the contractor have to achieve) The existing air reticulation system in the coal belt feeder chamber is not operational and the Contractor needs to modify the system and return it to its operational capability (performance specification will be provided as an Addendum during tender stage) An Addendum will be provided during tender stage to add the fire protection scope for the tippler. 56

57 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Electrical Supply 2 new VSD’s to be used to drive the tandem tippler Supply 2 VSD driven motors for the barrel drives The Contractor must do a study to determine the best option for the VSD configuration. The Contractor must also determine if brake resistors AFE drives are required for the tandem tippler VSD’s to operate correctly and safely Lighting in the tunnel Retrofit circuits in the 380V coal tippler boards 1&2 (GE switchgear). Testing of affected cables All switchgear work to comply with Eskom standard (240-56227516 ) 57

58 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Civil To design, manufacture, install and implement a dual sided drive system for the proposed Portal Indexer including foundations. Portal Indexer Runway/Rails Design and construction of the new civil works Portal Indexer Guides and Support Rollers: New foundation. Demolition of an existing concrete apron slab and design and construction of a new foundation. Stripping out of the existing guide rail, maintaining the existing anchor bolts and the installation of new steel pedestals Portal Indexer Racks (dual drive with gearing on east and west side) Two new drive racks onto the steel pedestals with associated steelwork to facilitate alignment of the rack and stripping out the existing rack. End Stop Buffers The existing End Stop Buffers refurbished and reinstalled onto the existing foundation anchorage and demolition of the existing redundant end stop anchor bolts and pedestals. 58

59 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Civil (Continues) Indexer Enclosure Dumper and indexer to be housed in a weatherproof roofed shed with sufficient access points to allow maintenance access to all installed equipment. Refer to Annexure A, Civil drawings for the enclosure sketch. The Contractor prices this under the activity schedule as a takeout item. Dumper and indexer to have permanent portal crane with a maximum lifting capacity based on the installed equipment mass tonnage 59

60 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Civil (Continues) Tippler Structure Repairs A visual inspection of damages has to be undertaken in order to quantify the scale and extent of remedial work required so that a further 45 years operational lifetime can be realized. The Contractor proposes and allows for detailed investigations, inclusive of testing required during the execution of the work. The proposal forms part of the tender submission. Based on the visual inspections done during the tender phase, the Contractor is required to allow for the repair works in the programme of works. The Contractor is responsible for proposing repair methodologies required. 60

61 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Civil (Continues) Train Holding Device Existing concrete apron slab will require demolishing locally over the footprint of the base pads and made good again on completion of the new foundations. Belt Feeder Conveyor A visual inspection of damages has to be undertaken in order to quantify the scale and extent of remedial work required so that a further 45 years operational lifetime can be realized. The Contractor proposes and allows for detailed investigations, inclusive of testing required during the execution of the work. The proposal forms part of the tender submission. Based on the visual inspections done during the tender phase, the Contractor is required to allow for the repair works in the programme of works. The Contractor is responsible for proposing repair methodologies required. 61

62 SECTION 7: TIP (Tippler) TIPPLER (STRIPPING/REMOVAL AND INSTALLATION) Civil (Continues) Dumper structural integrity inspection and repair The Contractor conducts a detailed inspection on the dumper structure for any defects and provides a report with recommendations including prices for the repairs during the execution of the works. During the tender, the Contractor prices for the detailed assessment tests and reports. The Contractor makes allowance in his schedule for time to repair defects. The Contractor does not price for the actual repairs during tender stage. The Contractor will be instructed by the Employer to execute the repairs after the assessment and recommendations are accepted by the Employer. Maintenance Plan The Contractor develops and documents the preventative maintenance plan 62

63 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Bulk Materials Handling Design, supply, manufacture, install,cold and hot commissioning of both the take out conveyors including the transfer points Design, supply, manufacture, install,cold and hot commissioning of a new stacker feed conveyor including the transfer points Design, supply, manufacture, install,cold and hot commissioning of the extension of both the overland conveyors Interface to the tail end of the existing overland conveyors Interface to the existing take-out conveyors at the magnetic structure house The entire engineering Works to ensure a fully functional conveyor systems with a capability to conveyor 14Mt of coal per annum 63

64 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Control and Instrumentation Conveyor protection system including HECU and protection devices for the Tippler Take-out conveyors Conveyor protection system including HECU and protection devices for the Stacker Feed conveyor Protection devices for the extended section of the Overland conveyors. Full integration of the new protection systems into the existing systems and DCS. Interfacing to the new transfer house drainage sump pump. Level detection for the new transfer house drainage sump 64

65 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Control and Instrumentation (Continues) Interfacing the new HVAC systems (see LPS scope) to the DCS as required. Re-routing of fibre optic cables running up the 4000 t silo that is being demolished. Re-routing of trunk cabling for the junction boxes associated with the pollution control dam equipment. Interfacing to existing magnetic separator and mobile feeder. Supply of various field devices such as mass meters, metal detectors and powder markers, tachometers. Supply of linear heat fire detection system and interfacing this into the existing Ziton system. 65

66 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Control and Instrumentation (Continues) Supply of local control panels and junction boxes as required by the Works Supply of all cabling and racking required to complete the Works Interfacing to the switchgear of all new/existing electrical drive’s as required by the Works Logic and HMI changes to accommodate new Plant, equipment and functionality – to be compiled and tested offline prior to implementation All new signals are made available on Plant Historian. All control is performed by the ABB DCS and only ABB or an ABB accredited contractor performs work on the DCS. 66

67 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Low Pressure Service HVAC Direct expansion air conditioning system with fully integrated fresh air system to service the coal stockyard substation Associated Electrical switchgear & cabling for complete HVAC Works Associated Controls, Building Management System (BMS) capability and accessories for complete HVAC Works Associated building and civil Works for complete HVAC Works Interfacing with fire detection system 67

68 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Low Pressure Service (Continue) Fire Protection Perform a Fire Protection/Detection Assessment (FPDA) New water supply pipework with hydrants for fire protection of all associated conveyors Interfacing with the current fire protection system for full operation of the new fire protection equipment Associated Controls, Building Management System (BMS) capability and accessories for complete fire protection Works Associated electrical and civil Works for complete fire protection Works Decommissioning and removal of all redundant equipment and make good where required for complete fire protection Works 68

69 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Low Pressure Service (Continue) Water reticulation system Replacement of a section of the pipeline supplying water from the pollution control dam to the main ash conditioning water supply tank and the coal stockyard dust suppression water supply tank Interfacing with the current pipeline supplying water from the pollution control dam to the main ash conditioning water supply tank and the coal stockyard dust suppression water supply tank Relocation of the current coal dust suppression water supply tank & pump station Associated Electrical switchgear & cabling for complete water reticulation Works. Associated building and civil Works for complete water reticulation Works Decommissioning and removal of all redundant equipment 69

70 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Electrical (Mdu update accordingly) Disconnect the conveyor (00EAB21 & 22) motors fed from the 6,6kV Coal Stockyard Boards 3 &4 (2 x motors per conveyor). Modify two circuits from panel 7&8 in 6.6 kV Coal Stockyard board 3&4. circuits to supply the ring (cable feeder scheme). Supply new MV motors (2 x 600 kW at 6.6 kV). Cabling work (test and install). Retrofit circuits (MCBs and DOLs) in the 380V coal stockyard boards 1&2 (GE switchgear). Modifying and calculation of new protection settings 70

71 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Electrical (Continues) Disconnect the existing coal bin feed conveyor 11 and coal bin feed conveyor 22 motors in order to create circuits for the new 600 kW conveyors 00EAB21 and 00EAB22 (Take out conveyor). The conveyors (00EAB21) and (00EAB22) to be disconnected from 6,6kV Coal Stockyard Board 3&4 are to be connected in the new circuits. All MV switchgear Modifications to comply with Eskom standard 240- 56357424. 71

72 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Civil Complete design in accordance with the requirements of this specification and standards list in the works Design scope includes the design of: Foundations Transfer house building Conveyor belt splicing station for each conveyor belt (this splicing station must include hydraulic belt clamps and tensioner) Incline conveyor gantries Overland conveyor structures Extension of existing overland conveyors Modification of the existing stacker feed transfer house and other supporting structures of the coal handling plant. Earthworks and terracing 72

73 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Civil (Continues) Crawl beams provided to all areas required for maintenance and installation of plant equipment. The safe working load of each crawl beam is clearly shown on each crawl beam Provision must be made for a reinforced concrete slab to support the mobile feeder that would feed on the transfer house incline conveyor Sizing and optimizing of the different components All calculations relating to the civil work and all drawings are prepared and submitted to the Project Manager. Provision of all embedded anchor bolts, sleeves, anchors and other miscellaneous embedded parts required for the installation of all plant and structural steel work, including if necessary setting templates required for the placement of anchor bolts/embedment. 73

74 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Civil (Continues) Crawl beams provided to all areas required for maintenance and installation of plant equipment. The safe working load of each crawl beam is clearly shown on each crawl beam Demolition and removal of electrical substation and the four thousand ton silo with supporting structures Dismantling and removal of existing Assizing complex, surge bin conveyors and the portion of the tippler take-out conveyor, 4000ton silo belt feeder Provision of all scaffolding, site craneage, lifting equipment, etc. which are required by the Contractor Excavations and casting of all foundations and floors for the plant. 74

75 SECTION 8: CON (Conveyor) CONVEYOR (STRIPPING/REMOVAL AND INSTALLATION) Civil (Continues) Demolish a portion of the existing stormwater canal to accommodate the new transfer house Design and construct a new portion of the canal according to the Works Info Provide storm water drainage for the new conveyor section New silt sump for the new transfer house building Any other necessary storm water and drainage for the conveyor system. 75

76 Thank you Insert image here


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