nioh specification for construction of a … plinth for the chiller e. new plinth for the generator...
TRANSCRIPT
TENDERER……………………………
CONSULTING ENGINEER Triocon Consulting Engineers (Pty) Ltd 203 Witch Hazel Drive Highveld Technopark Centurion
Project: C/2206/M3
NIOH
SPECIFICATION FOR CONSTRUCTION OF
A BSL 3 FACILITY FOR THE NIOH,
BRAAMFONTEIN
JOHANNESBURG
Triocon Consulting Engineers (Pty) Ltd
National Health Laboratory Service
National Institute for Occupational Health
Air conditioning and Ventilation Systems
Project Specification
2
PROJECT SPECIFICATION
Triocon Consulting Engineers (Pty) Ltd
National Health Laboratory Service
National Institute for Occupational Health
Air conditioning and Ventilation Systems
Project Specification
P
PART 1 PROJECT SPECIFICATION 1.0 GENERAL
This contract describes the design, manufacturing, delivery, installation, commissioning, testing and
handing over in a fully working state new the BSL 3 for the National Institute for Occupational Health
(NIOH), Hospital street, Braamfontein, Johannesburg.
Over and above the equipment specified in this section, the Contractor must make allowance for all
other or additional equipment required for a full working installation. This shall include all safety
equipment required by the OHS Act and Regulations pertaining to the various systems installed.
By submission of a tender the tenderer will be deemed to have acquainted himself fully with the tender
document, local requirements and laws and all aspects of the work envisaged in the documents prior to
the submission of his tender. Uncertainties and doubts as to the meaning and interpretation of items in
these documents must be submitted to the consulting engineer to have them explained, rectified or
cleared before tenders are submitted.
The Tenderer must provide all plant, scaffolding, cranage, ladders, etc and must make due allowance in
his tender therefore. Tenderers shall acquaint themselves with local site conditions such as access to
the site, size and type of access, supply of labour, workshop space, transport, loading and unloading
facilities, scaffolding, tackle and tools needed for the erection of the installation. Additional claims by
the Contractor, which may arise from ignorance of the site conditions, will not be considered and
tenderers are requested to visit and inspect the site.
No claim will be entertained for the working of overtime, disruption, out of sequence activities, additional
supervision and/or plant which might be necessary to achieve the program dates.
The Tenderers attention is drawn to the fact that the tender for this contract work is to be NET and must
not contain (directly or indirectly) any allowance, discount, payment or refund in favour of any person,
company or concern whatsoever, nor will any such allowance, discount, payment or refund be made, or
credited.
The Tenderer shall ensure that all items tendered for are priced exclusive of Value Added Tax (VAT).
VAT shall be added to the exclusive amount to arrive at the total tender amount (inclusive of VAT) and
the tenderer is required to complete the form of tender as set out.
2.0 THE SITE
This site is located on the NIOH Building, 25 Hospital Street, Braamfontein, Johannesburg.
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3.0 PROGRAMME
The start and completion dates of the works are to be agreed with the Client prior to commencing any
work.
No claim will be entertained for the working of overtime, disruption, out of sequence activities, additional
supervision and/or plant which might be necessary to achieve the programme dates.
4.0 SCOPE OF CONTRACT
This project entails the construction of a BSL 3 facility in the existing aerosol lab in the NIOH- building.
The Principal Contractor shall be a HVAC specialist contractor. The principal contractor shall appoint
various specialist subcontractors to carry the builder’s works, electrical works etc. The scope of works
will comprise of, but not be limited to the following:
Scope of Builders works
The builder’s works shall comprise of but not be limited to the following. Refer to drawing.
a. Supply and installation of cold room panels, and alterations to the layout of the existing facility, in
order to create ante rooms and plant area.
b. Sealing of all penetrations, joints, frames etc. with a medical grade sealant to ensure an airtight
room.
c. Alterations to the ceiling structure of existing lab to create ceiling space for plant area
d. New plinth for the chiller
e. New plinth for the generator
f. Supply and installation of a portable effluent treatment device for the laboratory. Refer to the
schedules
g. All penetrations and making good of all trades
h. Provision of a drain point for the air conditioning system
i. Provision of a 15mm potable water connection to the chiller plant area.
j. Co-ordination with other services and principal contractor to ensure the successful completion of
the project.
Scope of Electrical Works
Refer to the electrical specification and drawings for further details
a. Supply, Installation and Commissioning of a new emergency backup power generator.
b. Supply, Installation and Commissioning of a new Uninterruptable Power Supply.
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c. Supply and Installation of new lighting systems
d. Supply and installation of new small power reticulation
e. Supply and Installation of new electrical distribution board
f. Supply and Installation of new electrical power supply from the existing transformer to the new DB.
g. Supply, Installation and Commissioning of a new Access control system for the new lab
h. Integration of all electrical services with other services as specified
i. Co-ordination with other services and principal contractor to ensure the successful completion of the
project.
Scope of Mechanical Works (Principal Contractor)
a. Supply and installation of a low noise, air cooled chiller to provide chilled water to the air handling
unit.
b. Supply and installation of a chilled water circulation pump to the chiller plant.
c. Supply and installation of one minimum 500 L capacity insulated chilled water buffer tank for chiller
plant.
d. Supply and installation of all chilled water piping and ancillaries as indicated on the concept design
drawings.
e. Supply and installation of ducting and diffusers as indicated on the concept design drawings.
f. Supply and installation of exhaust fan-filter system as indicated on the concept design drawings.
g. Supply and installation air-handling unit with electric heating and chilled water cooling coils as
indicated on the on the concept design drawings.
h. Supply and installation of condensate drains from all condensate drain pans to the nearest drain
point. It will be the responsibility of the Contractor to ensure that the condensate drains are
individually reticulated to the nearest foul water drain.
i. Connection of the chilled water piping to the make-up water point provided by the building
subcontractor.
j. The electrical scope of works pertaining the mechanical installation comprise of the necessary main
and electrical sub-panels, motor control centre, switchgear, contactors, isolators, starters, motor
protection units, speed controllers, etc, including all the necessary field wiring and connections to the
various systems unless otherwise indicated.
k. A central master control system shall be located in close proximity of the HVAC plant. A remote
control panel shall be located at the entrance to the new facility. Refer to the concept design
drawings and detail specification.
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l. Testing, commissioning, certification and ensuring the sign off by the Client and his representatives
of all systems.
m. Coordination of all services, including but not limited to electrical and builder’s work, including the
timeous provision of workshop drawings and relevant details.
n. Provision for three copies of operating and maintenance manuals including installation drawings.
Installation drawings shall also be available in AutoCAD format. The contents of the manual shall be
as specified in the Standard Specifications. NOTE: The installation shall not be considered
practically complete or complete for beneficial use until the systems have been properly
commissioned and approved and O&M manuals have been submitted that incorporates all the
commissioning figures and data. 5% of the tender amount shall not be certified until the approved
O&M manuals have been received.
o. The 12 months guarantee and maintenance of the installed systems.
p. Training of users and maintenance staff.
q. Automatic water treatment system for the chilled water systems.
r. A provisional amount has been included in the tender breakdown for scope of work not yet defined.
Note: Tenderers shall note that the scope of work may change due to budget constraints and that the tendered rates will apply to any changes in the scope of work.
5.0 OTHER CONTRACTORS AND SPECIALISTS
It will be required of the Contractor to appoint the appropriate subcontractors and other specialist
contractors. Employment of these contractors and specialists shall in no way exonerate the Contractor
from his obligations in terms of this contract.
6.0 WORK BY OTHERS
Works by others shall be carried out to the Principal Contractor’s requirements, as detailed on his
builder’s work/detailed shop drawings.
6.1 Builders Work Items
Provision of openings in walls, floors, roofs etc. marked out by the Principal Contractor.
Provision of openings in ceilings, suitably stiffened if necessary for the fixing of diffusers.
Provision of any access hatches required.
Supply and building in of timber sleeves.
Building in of any steel sleeves or frames (supplied by the Principal Contractor).
Installation of door grilles (including the specified screw fixing). The door grilles are to be
supplied to the site by the Principal Contractor.
Caulking in of holes around ducts and pipes penetrating floors and walls.
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Casting or forming of any plinths or platforms on which the equipment is to be mounted.
Provision of a trapped gully or connection into the soil system (into a WHB drain above a U-
trap)
7.0 ELECTRICAL SUPPLY
7.1 During construction temporary electrical supply may be made available by the Client. The supply shall
be 400 Volts, 50Hz, 3 phase or alternatively 230 Volts, 50 Hz, single phase. This supply is not
guaranteed.
7.2 Normal operating voltage shall be at 400 Volt, 3-phase, four wires or 230 Volt, single phase, three wires.
7.3 This contract includes for the provision of electrical panels, sub-panels and wiring for the air conditioning
systems and provision of electrical power to equipment. The electrical subcontractor shall provide a
capped 3-phase power to the air conditioning panel in as indicated on the drawings, but the air
conditioning contractor (Principal Contractor) shall make the connection of the cable to the main isolator
on the AC panel. Wiring between the panels and the equipment shall be done as part of the AC &
Ventilation Systems Contract. Also included in this contract is the electrical power and control wiring for
the AC systems.
7.4 At completion of the contract a Certificate of Compliance for the electrical work carried out shall be
provided to the Consulting Engineer and a certified copy shall be included in the O&M manual.
8.0 COMPLIANCE WITH REGULATIONS
The installation shall be erected and carried out in compliance with:
a. The Occupational Health and Safety Act 85 of 1993 and as amended incorporating SANS
0142.
b. The SANS Code of Practice for the Wiring of Premises No. 0142 of 1981, as amended.
c. The local Municipal by-laws and regulations as well as the regulations of the local Supply
Authority.
d. The local Fire Regulations.
e. The Standard Regulations of any Government Department or public service company where
applicable.
f. SANS 0400 : Building regulations
g. Other relevant SANS regulations pertaining to HVAC and Electrical installations. SANS 1238
and SANS 10173 are included for reference.
The Contractor shall at his cost issue all drawings and notices in respect of modification of the
installation to the local authorities, and shall indemnify and exempt the Employer from all losses, costs
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or expenditure which may arise as a result of the sub-contractor's negligence to comply with the
requirements of the regulations stipulated above. No work shall be commenced by the sub-contractor
prior to the approvals by the local authority of the relevant drawings or applications to perform work.
It shall be assumed that the sub-contractor is conversant with the abovementioned requirements.
Should any requirement, bylaw or regulation, which contradicts the requirements of this document,
apply or become applicable during erection of the installation, such requirement, bylaw or regulation
shall overrule this document and the sub-contractor shall immediately inform the Employer of such a
contradiction. Under no circumstances shall the sub-contractor carry out variations to the installation in
terms of such contradictions without obtaining written permission to do so from the Employer.
Also refer to the Standard Specification.
9.0 SERVICE CONDITIONS
All equipment and capacities specified herein shall be rated at the following conditions:
Altitude: 1750 m
Temperature: Summer / Cooling Winter / Heating
Ambient Air 30 °C (DB), 20°C (WB) 2°C (DB), 0°C (WB)
Room set point range 15 °C to 35 °C (+/- 0.5 °C)
40 % rh to 70 % rh (+/- 5%)
Ventilation rates: 2-20 ACPH
Max noise Levels: Laboratory spaces NC 45
Outside NC 50
Note: The correct system configuration and final sizes of ducts and attenuators must be
calculated and engineered by the A/C sub-contractor to ensure that the sound levels do not exceed the above criteria.
10.0 WORKMANSHIP AND QUALITY OF MATERIALS
The sub-contractor shall employ only competent artisans to perform construction and installation work
on site.
The contract shall be executed with the best workmanship in a workmanlike manner to the satisfaction
of the Employer. Should any workmanship not be to the satisfaction of the Employer, it shall be rectified
at the cost of the sub-contractor.
The sub-contractor shall remain responsible for the correct and complete delivery of the installation.
Inspection by the Employer shall not release the sub-contractor from his responsibility.
Only material of high quality and suitable for the climatic conditions of the site shall be used and shall be
subject to approval of the Employer. All material shall conform in respect of quality, manufacture, tests
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and performance, with the requirements of the SANS 10142 or where no such standards exist, conform
to the appropriate current Specifications of the British Standards Institution. Materials manufactured in
South Africa shall as far as possible be used and where applicable shall bear the SABS/SANS mark.
Imported materials shall comply with the requirements of the appropriate B.S. or I.E.C. specification. All
materials shall be suitable for the conditions under which the materials are installed and used.
Should the materials or components not be suitable for temporary use under site conditions, then the
sub-contractor shall provide suitable protection at his own cost until these unfavourable site conditions
cease to exist.
11.0 DESCRIPTION OF THE FACILITY
The new BSL 3 facility will be utilized as an aerosol room, where the effect of different room conditions
and air flow rates on the concentration of aerosol will be studied. The room temperature set point, the
humidity set point, and the airflow will be set to a certain condition. Aerosols, such as tuberculosis, will
then be released in the lab, and the air inside the lab will then be sampled over time to determine the
aerosol decay.
It shall be noted then, that unlike in a conventional BSL3 facility where the laboratory where all the
processes are carried out in biosafety cabinets, the envelope of this facility is the primary barrier of
containment. It is therefore vital to ensure the integrity of the laboratory.
The laboratory shall have a conventional room layout with a clean change room, a dirty change room
and the laboratory itself.
A conventional 600 x 600 ceiling structure, suitable for the installation of a drop in ceiling, shall be
installed at 4 m AFFL. The installation of ceiling tiles will not form part of this contract. The ceiling
structure shall be supported with steel rods from the top of the lab. Special care shall be made to ensure
that all penetrations are sealed air tight and vapour proof.
11.1 DESCRIPTION OF THE HVAC SYSTEM
A variable volume, full outdoor air handling unit shall be located in the allocated plant area on top of the
change rooms. This air handling unit shall be equipped with primary, secondary and HEPA filtration,
variable speed drive, a BCC fan, chilled water cooling valves, electric heating and duct mounted steam
humidifier.
The supply air ducting shall be pressure tested from the air tight damper to the envelope of the lab. The
ducting shall terminate in a downwards facing spigot, complete with a 2.5 m long aluminium stiff flex.
The end of the flexible duct shall be equipped with a cam lock type strap to allow for easy changing of
diffusors.
The air handling unit shall be supplied with chilled water from a new air cooled chiller located in
courtyard to the east of the laboratory. The chilled water generation plant shall be complete with a
circulation pump, an insulated buffer tank and insulated chilled water piping.
A bag in/bag out extraction system, equipped with secondary and HEPA filters in safe change housing
shall be installed next to the AHU. This unit shall be complete with a decontamination loop, to allow for
in situ decontamination of the filters.
TB lab section
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Stages one and two (clean and dirty change rooms)
An outdoor air fan, with uninsulated sheet metal ducting, which distributes filtered 100% outdoor air to
the outer change room. The air moves through the door grille and is extracted from stage two.
Stage three (BSL three lab)
A variable volume air handling unit mounted vertically on a plinth unit of double skin construction
manufactured either by Air Options or Heat Pump International distributes filtered 100% outdoor air to
the laboratory.
The air handling unit is supplied with chilled water via the chilled water piping system from the air
cooled chilled water plant area located in the light well on the western side of the laboratory. The unit
has a three-way modulating valve, which regulates the amount of water to the unit. The three-way valve
is controlled by the direct digital control (DDC) system, which senses the supply and exhaust air
temperature and modulates the valve accordingly. A temperature sensor located in the supply duct shall
through a controller and actuator adjust the position of the chilled water control valve in order to
maintain the supply air set point. When heating is required the chilled water control valve shall be fully
closed before the heating control is activated. Heating shall be by electrical resistance type heaters and
be controlled via a current valve, similar to the control philosophy for cooling.
The exhaust air system draw exhaust air from the laboratory through safe-change HEPA filter banks
before being discharged vertically. Inside the laboratories the air is extracted through EGG crate grilles,
complete with volume control dampers.
All systems shall be powered via the essential power circuits, and shall operate with a duty only
arrangement.
Special, separate controls and interlocks are required for this system.
The ductwork for this entire installation shall be sealed ducting according to the requirements of high-
pressure ductwork and as per current good practise for BSL-3 systems. All ductwork shall be tested for
leaks and certified to be leak free. Pressure testing is described elsewhere in this document.
Supply Air Temperature Control
Temperature control of the supply air system is via an exhaust air duct temperature sensor to be
mounted in the exhaust air duct after the safe-change HEPA filters but before the exhaust fans.
Washable primary, cartridge type secondary, and HEPA filters shall be provided on the supply. Suitable
provision shall be made for the easy removal and replacement of the filters. The manufacturer of the
air-handling unit shall provide the necessary penetrations for manometers and differential pressure
sensors to measure the pressure drop across each filter bank. The manufacturer shall neatly seal the
penetrations.
Basic functions required of system
The nature of work carried out in the BSL-3 laboratory require the following minimum functionality:
The systems shall maintain a net inflow of air into the laboratory at all times, in other words,
airflow shall be from outside laboratory and out via the HEPA filtered extraction system.
This functionality shall continue under power outage conditions, in other words, the systems
shall automatically restart from essential power upon a power failure.
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Interlocks between fan systems shall be such that it is impossible to overpressure the
laboratories, i.e. if the duty exhaust fan should fail, the supply air systems shall automatically
stop due to hardwired interlocks.
Separate alarm monitoring of differential pressures between outside, anteroom and laboratory
is required in parallel with control systems. These alarms shall be visual and audible in the
space as well as connected to the central building alarm monitoring systems via voltage free
contacts. “Magnehelic” type sensors shall be used for local visual indications to users inside
the spaces.
Differential sensors across filters shall warn users when filters approach “dirty” conditions.
HEPA filters shall be 99,997% effective according to the DOP test and shall be housed in safe-
change filter housings complete with non-return dampers and 100% shut-off dampers. Refer to
section 14 for further details.
Connection points for differential pressure measurement and sterilisation shall be integral to
the housing as manufactured. The housing on the roof shall be suitable for a long life under
outdoor use conditions at the site.
Pressure differential control
Maintaining a negative pressure inside the laboratory and the associated net inflow of air is
achieved by use of variable speed fans.
The supply air to the BSL 3 lab is supplied at a constant pressure measured after the supply
HEPA filter boxes. The variable speed drive of the supply air fan controls this by means of a
velocity sensor.
An individual exhaust system serve the BSL 3 laboratory. The exhaust system comprises of
duty only fan with separate speed controllers. The fan speed is controlled in each case to
maintain a set differential pressure of 30 Pa between the passage and the laboratory itself. The
exhaust system exhausts more air from the laboratories that what is provided, thereby
maintaining a negative pressure.
The supply and exhaust fans shall be interlocked mechanically to prevent the net outflow of air
i.e. the room pressure from being positive relative to ambient. When the lab is started up, the
exhaust fan shall lead until the negative pressure is established, before the supply air fan is
started.
Differential pressure between inside and outer change room is controlled by adjusting the door
transfer grille open area in the respective door connecting the two spaces. Likewise the
pressure differential between inner change room and laboratory.
Visual display of differential pressures (applicable to BSL 3 laboratory)
Four Magnehelic type differential pressure indicators with contacts for alarm switching shall be
mounted in a panel as indicated on the drawings. Connections shall be provided so that
differential pressures between either passage and the outer change room, inner change and
outer change, and inner change and the BSL lab can be read. Instrumentation shall be as
follows:
TABEL 1: Differential pressure indicators and alarms
Instrument Magnehelic #1 Magnehelic #2 Magnehelic #3 Magnehelic #4
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DP Identification ∆P1 ∆P2 ∆P3 ∆P4
DP between stages (Pa) +15 -30 -15 -30
DP relative to passage
(Pa)
15 ± 5 -15 ± 5 -30 ± 5
High pressure warning Orange light Orange light
Low pressure warning Orange light Red light + bell
Alarms
The following alarm functions shall be installed:
A warning lamp panel shall be installed at the entrance to EACH of the rooms c/w with warning
bell. The electrical and electronic systems shall operate the lights and bell as follows:
Green Light: All systems are functioning correctly
Orange light: System requires maintenance. This could be a duty fan out of service, filters that
require cleaning or replacement, etc. – not critical alarm.
Red light and warning bell: System not able to maintain differential pressures due to critical
failure of equipment – laboratory should be evacuated.
The following table presents the requirements per above:
TABEL 2: Differential pressure alarms
Orange light Red light + bell
Differential pressure ∆P1 low x
“ High x
Differential pressure ∆P2 low x
“ High x
Differential pressure HEPA supply High x
Differential pressure HEPA exhaust High x
Exhaust fan EA1 fan fail x
Air handling supply fan fail
Biological safety cabinet alarm activated (common rail
fault)
x
Temperature control outside limits x
Relative humidity control outside limits x
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12.0 VENTILATION SYSTEMS
There is one extract system:
Pressurization fan for the clean ante room with a nominal duty of 50 l/s at 150 Pa total
pressure.
13.0 GENERAL TECHNICAL SPECIFICATIONS FOR NEW AHU
13.1 GENERAL
Air Options or similar approved equipment is specified for this project.
Please note: Any deviation from the specified equipment shall be formally approved by the Consulting
Engineer and Head of Mechanical Engineering at the NHLS before the order is placed.
The AHU shall comply with the following technical specifications.
13.1.1 AIR HANDLING SECTION
PLENUM CONSTRUCTION
The AHU air handling section of the unit shall utilize a 50mm thick double skinned interlocking panel
construction system to form the plenum of the air handling unit. The AHU panels shall be manufactured
from purpose designed interlocking 50mm thick panels of fire retardant polystyrene clad internally and
externally with chromadek treated sheet metal that provides a high quality corrosion resistant finish to
the air handling unit that is suitable for either internal or external mounting.
HINGED ACCESS DOORS
The AHU units shall be fitted with heavy duty powder coated galvanized hinged access doors as
standard. The galvanized steel door frame supporting the heavy duty access door shall be secured to
the external surface of the air handling unit creating a robust positive sealing, hard wearing service
access to the air handling unit.
COMPONENT SERVICE ACCESS
While the internal components are all fully accessible via the access panels detailed above, they are
also removable from the air handler via the purpose designed panels described above that are
removable should it be necessary.
GALVANIZED BASE FRAME
The air handling unit shall be fitted with a hot dipped galvanized steel channel base frame that lifts the
AHU off the floor of the plant area.
PAINTWORK
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The total panel construction of the air handling unit shall be white Chromadek. The heavy duty
galvanized sheet metal access panels shall be powder coated white.
ON SITE RIGGING/LIFTING
The air handling units shall be fitted with heavy duty lifting lugs fixed to the base of the unit.
13.2 ELECTRICAL POWER, CONTROL SYSTEM & OPERATIONAL
The air handling unit shall include a complete power supply electrical panel together with all electrical,
and refrigeration controls and safeties to ensure the full and safe operation of the equipment.
All equipment fitted shall be wired and tested fully prior to dispatch.
Refer to the controls section of the document for a detailed description of the controls system.
13.3 CONDENSATE DRAINS
The AC contractor is responsible for taking his drains with a deep U-trap (approximately 100 mm min.
deep) to the trapped gully. A drainpipe can also be used for drainage of air vents.
13.4 COOLING COILS AND ELECTRICAL HEATING
For coil selections, refer to Part 6, Schedule of equipment. The coil selection in Part 6 serves as a
guideline for tendering purposes. The A/C contractor shall ensure that the coil selected for the air
handling unit will be able to provide the room conditions as stated earlier in the document. The cooling
coils shall be copper coils with aluminium fins.
The electrical heating coils shall be factory fitted. Refer to Part 6 for the heating capacities.
13.5 COOLING COIL FACE VELOCITIES
Coil selections are to be made for face velocities of the order of 2, 25 m/s. The face velocity shall not
exceed 2, 5 m/s.
13.6 FILTER BANKS
The filtration system shall comprise of primary, secondary and HEPA filtration systems and shall be
manufactured and installed by the supplier as per section 14 of this document.
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Provision shall be made in the filtration section of the AHU for scan testing the HEPA filter.
14.0 GENERAL TECHNICAL SPECIFICATION FOR SUPPLY AND EXHAUST FILTRATION SYSTEMS
14.1 GENERAL
14.1.1 RELATED DOCUMENTS
This part shall be read in in conjunction with the drawings and technical schedules as found in the
annexures.
14.1.2 WORK INCLUDED
a. Containment filter housings
b. Prefilters
c. High Efficiency Particulate Air (HEPA) filters
d. Isolation dampers
e. Differential pressure filter gages
14.1.3 RELATED SECTIONS
a. Examine all drawings and criteria sheets and all other Sections of the Specifications for
requirements, which affect work under this Section whether or not such work is specifically
mentioned in this Section.
b. HEPA filters to be furnished by the containment manufacturer.
14.1.4 REFERENCES
a. Applicable provisions of the following Codes and Trade Standard Publications shall apply to the
work under this Section whether or not such work is specifically mentioned in this section.
b. Applicable provisions of the following Codes and Trade Standard Publications shall apply to the
work under this Section whether or not such work is specifically mentioned in this section.
c. ASHRAE – American Society of Heating, Refrigeration and Air-Conditioning Engineers
d. ASHRAE 52.2: Method of Testing Air-Cleaning Devices in General Ventilation for Removal
Efficiency by Particulate Size (Minimum Efficiency Reporting Value)
e. ASME – American Society of Mechanical Engineers
f. AG-1-2003: Code on Nuclear Air and Gas Treatment
g. NQA-1-2008: Quality Assurance Requirements for Nuclear Facility Applications (QA)
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h. N509-2002: Nuclear Power Plant Air Cleaning Units and Components
i. N510-2007: Testing of Nuclear Air Cleaning Systems
j. N511-2007: In-Service Testing of Nuclear Air Treatment, Heating, Ventilating, and Air-Conditioning
Systems
k. BPVC-IX-2007: Welding and Brazing Qualifications
l. ASNT – American Society of Non-destructive Testing
m. SNT-TC-1A (2006): Recommended Practice No. SNT-TC-1A: Personnel Qualification and
Certification in Non-destructive Testing
n. AWS – American Welding Society
o. D9.1M/D9.1:2006: Sheet Metal Welding Code
p. DOE – US Department of Energy
q. HDBK-1169-2003: Nuclear Air Cleaning Handbook
r. IEST – Institute of Environmental Sciences and Technologies
s. IEST-RP-CC001.4: HEPA and ULPA Filters
t. IEST-RP-CC002.2: Unidirectional Flow Clean-Air Devices
u. IEST-RP-CC008.2: Gas-Phase Adsorber Cells
v. IEST-RP-CC034.2: HEPA And ULPA Filter Leak Tests
w. UL – Underwriter’s Laboratory
x. UL 900: Air Filter Units
14.1.5 QUALITY ASSURANCE
a. Filter media shall be UL 900 listed, Class 1 or Class 2 as specified.
b. A written quality assurance program must be established for all components of the containment
filtration system and the manufacture shall meet and conform to all of the sections of the ASME
NQA-1 quality assurance program.
c. Assemble filters and housing components to form a containment filtration system from a single
manufacture (excepting vended components such as differential pressure gages and valves).
14.1.6 SUBMITTALS
See General Conditions for additional requirements.
Submit product data:
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a. Bid Documents: In order to validate the Filter Housing Offer fully meets the drawings and
specification, the Housing Manufacturer shall furnish the following qualifying documentation with
their Bid.
b. Statement of complete scope of supply.
c. Statement that clearly states how the scope of supply meets the specification and a listing of all
non-compliant features.
d. Supporting documentation to demonstrate specification compliance.
e. Submit appropriate catalogue cut sheets related to the bid offer.
f. Submit validation reports for the following:
g. R&D report validating the offered upstream test challenge injection section operates within the
specified parameters
h. Validating the automated function of the scan section.
i. Validating the ability of the in-situ scanning section to locate and size leaks in both high-capacity
and V-Bed HEPA filters
Engineering Submittal Documents: The selected Offeror shall furnish the following documentation
for Engineer Approval and Fabrication Release.
a. Submit a copy of the project specification stating line by line compliance.
b. Submit General Arrangement drawings for each Filter Housing size and configuration. As a
minimum, the following shall be included.
c. Overall dimensions
d. Interface locations and sizes
e. Mounting base anchor bolt plan
f. Service clearance dimensions
g. Filter and differential pressure gage requirements for each housing tag number
h. Submit an uncontrolled copy of the manufacturer’s Quality Assurance manual
Delivery Documentation: The Filter Box manufacturer shall furnish the following documentation in
conjunction with their equipment delivery.
a. Submit Housing Leak test reports
b. Submit Seal Surface Leak test reports
c. Submit Filter fit report
d. Submit final as-built drawings
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e. Submit three (3) copies of Operations and Maintenance manuals
14.1.7 EXTRA STOCK
a. Provide one extra set of all required prefilters and HEPA filters,
b. Provide two extra sets of all required PVC change-out bags and straps.
14.1.8 DELIVERY, STORAGE, and HANDLING
a. Housings shall be shipped to the jobsite on factory fabricated protective skids or containers (if size
allows). Items shall be blocked, anchored, braced and/or cushioned as deemed necessary to
prevent physical damage. All openings shall be covered. The housings and filters shall be stored in
a clean dry place and protected from weather and construction traffic. Housings shall be handled
carefully to avoid contact with carbon steel and damage to accessory components, enclosures and
finish.
14.2 PRODUCTS
14.2.1 ACCEPTABLE MANUFACTURERS CONTINGENT OF COMPLIANCE WITH SPECIFICATONS
A. Camfil Farr (Basis of Design)
B. Substitutions
1. Due to life safety concerns, this specification section describes highly specialized equipment and
components that are known to be included in the basis of design. Equipment and component
substitutions may be made at the time of bid. However, a full evaluation package shall be included
with the alternate manufacture’s proposal. The offeror shall clearly state the proposed
manufacturer’s offers of all equipment and components specified under this section. The offeror
shall provide a complete and detailed response to each paragraph of the contract specification.
The offeror shall clearly note after each specification paragraph one of the following responses: 1.
comply, 2. deviate, or 3. exception. For deviation or exception responses, the offeror shall fully
explain the deviation or exception. Detailed equipment drawings shall be furnished to demonstrate
full compliance with the dimensional requirements shown on the contract drawings. Any deviation
shall be clearly shown on the drawings of the proposed equipment. Any alternative bids not
including the above required information will be rejected. The Contractor shall bear to the
responsibility to furnish equipment in complete compliance with this specification. The owner or its
representative reserves the right to reject any deviation or exception if it does not meet the intent or
the requirements of this project.
2. All acceptable manufacturers shall be the producer of all of the products specified in this Section.
Vended products shall be limited to raw materials, fasteners, gages, damper operators and valves.
The specified filters shall be produced by the same company that produces the filter housings. The
offeror shall clearly identify all purchased components, weldments and assemblies from outside
sources. Failure to comply shall result in the rejection of the offered product.
14.2.2 BAG-IN/BAG-OUT CONTAINMENT FILTER HOUSINGS
A. General
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1. The Bag-in / Bag-out Containment Filtration system shall be Camfil Farr CamContain fully
integrated packaged units, that have been fabricated, assembled and pressure decay tested in the
same factory. Each system shall consist of the following housing sections and components
assembled into an integrated containment system:
a. flanged inlet transition
b. inlet isolation damper
c. in-place test injection section with decontamination valve assembly
d. Prefilter section
e. HEPA filter section
f. HEPA filter automated in-place scanning section with decontamination valve assembly
g. outlet isolation damper
h. outlet transition
i. assembly welded on to a mounting structure
2. The system shall be designed for the scheduled CFM as indicated on the contract documents at 10
inches water gage and the maximum design temperature shall be 130°F. The furnished system
shall be sized not to exceed the scheduled “clean” pressure drop across the containment system
from inlet flange to outlet flange, including the inlet and outlet bubble-tight dampers. The scheduled
“dirty” pressure drop assumes the “clean” HEPA filter initial pressure drop times two.
3. Access Doors
a. There shall be four (4) tie down latches per access door and they shall be manufactured in
such a manner that they pivot away from the bag-out port after they are released, therefore,
the latches do not impede the filter change-out process. The latch shall be designed to provide
both a retainer for the aluminium star knob and to eliminate the hazard of a sharp protruding
object.
4. Transitions
a. Each containment system shall be fitted with reducing transitions.
b. Transitions shall be constructed of unpainted 304L stainless steel and designed with
reinforcement to withstand a negative or positive working pressure of 10” water gauge. The
minimum acceptable sheet metal thickness shall be 16 gauge. They shall be attached to the
filter system by continuous seal welding. The adjoining connection to the transition shall be a 1
½” inch wide 7 gauge plate flange.
5. Change-out Bags
a. One (1) PVC change-out bag shall be furnished for each access port. Each bag shall have its
stock number rolled in the hem. The PVC bag material shall be 8 mil thick, yellow in colour,
with a translucent, taffeta textured finish and shall not stick together.
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b. For visibility during filter change-out, this bag shall include approximately 16 inches of clear
PVC at the mouth. Three (3) glove sleeves shall be built into the bag to facilitate handling the
filter during change-out.
c. All PVC bags of this design shall be produced by filter housing manufacturer and shall have
been tested by an independent laboratory to prove the bag's operability at extreme
temperature ranges of 0°F - 130°F (a test report verifying this test shall be furnished upon
request). A 3/16-inch diameter elastic shock cord shall be hemmed into the mouth of the bag
so that it fits securely when stretched around the bagging ring. To prevent the bag from sliding
off the bagging ring during the change-out operation, one (1) nylon security strap shall be
provided with each filter access port. Additionally, one (1) nylon cinching strap shall be
provided with each access port to tie off the slack in the PVC bag while the ventilation system
is operating.
6. Orientation and Handedness
a. The contract drawings shall determine the filter access side of each housing. The handedness
of a housing shall be designated as right hand or left hand. When looking in the direct of
airflow (i.e. as if standing inside of the housing with the air flow hitting the person’s back) of the
HEPA filter, if access is required on the right side, then the housing shall be determined to be
right hand access. If access is required on the left side from the above stated vantage, then
the housing shall be determined to be left hand access.
7. All pressure retaining weld joints and seams shall be continuously welded with no pores allowed.
Joints and seams requiring only intermittent welds, such as reinforcement members, shall not be
continuously welded. As a minimum, joints and seams shall be wire brushed and/or buffed to
remove heat discoloration, burrs and sharp edges. All weld joints and seams that are a portion of
any gasket-sealing surface (e.g., duct connecting flanges) shall be ground smooth and flush with
the adjacent base metal.
8. The upstream and downstream flanges shall have a 1 ½ inch minimum flange width. Flanges shall
be turned to the outside of the airstream to prevent contamination build-up and allow the customer
to connect mating ductwork from outside the housing.
9. All hardware on the HEPA filter housing and all mechanical components shall be 300 series
stainless steel, except for the nylon washers, tubing, and the cast aluminium doorknobs.
10. All welding procedures, welders and welder operators shall be qualified in accordance with ASME
BPVC-IX-2007: Welding and Brazing Qualifications. All production welds shall be visually inspected
per AWS D9.1M/D9.1:2006: Sheet Metal Welding Code and incorporates the workmanship
acceptance criteria described in sections 5 and 6.
11. The filter housing shall be manufactured under a quality assurance program that meets all the basic
requirements of ASME NQA-1, “Quality Assurance Program Requirements for Nuclear Facilities”.
The manufacture shall submit documented evidence they have been independently audited by
customers at least three (3) times within the last six (6) years to ASME NQA-1 requirements, and
successfully passed all three (3) audits. The final containment filtration system shall be completely
fabricated, assembled, tested and cleaned at the manufacturer’s facility. Sub-assemblies from
outside sources will not be acceptable. The Offeror shall certify their compliance with this
paragraph.
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12. The filter housing shall be tested for filter fit, operation of the filter clamping mechanism, and knife
edge alignment and leak tightness before leaving the factory. Both the filter sealing surface and the
complete assembly pressure boundary shall be leak tested by the “Pressure Decay Method”, in
accordance with N510-2007 - Testing of Nuclear Air Cleaning Systems, paragraphs 6 and 7.
Pressure readings are recorded once a minute until pressure decays to 75% of the test pressure or
for 5 minutes, whichever comes first. There shall be a maximum leak rate of 0.0005 CFM per cubic
foot of housing volume at 10 inches water gage.
14.2.3 Linear Isolation Damper
1. Damper shall be Camfil Farr Linear Isolation Damper. The damper shall be manufactured from 7
gauge, 14 gauge and 16 gauge type 304/304L stainless steel. The damper shall have a spun
stainless steel dish with a receptacle that contains a closed cell silicone sponge gasket. A mating
knife-edge shall be installed on the damper so that when the damper is actuated, the knife-edge will
seal against the gasket.
2. Damper shall be high-cycle, low torque linear type design. The damper mechanism shall operate
linearly, without rotation or pivoting of the damper dish. The required input torque to operate and
adequately seal the damper shall not exceed 25 pound-feet.
3. The linear damper design shall be manufactured in accordance with ASME NQA-1 and
ISO9001:2000 and qualified by cycle testing the assembly a minimum of 15,000 cycles. A qualified
design shall pass the above specified leak test requirements without any adjustments to the
assembly (including the gasket) throughout the cycle testing. Evidence of a successfully qualified
design shall be furnished prior to bidding.
4. Manually Operated Isolation Damper Operators
a. Damper shall be factory equipped with a manual actuator. Actuator shall be equipped with a
hand wheel. Actuator shall be a quarter-turn manual worm geared operator. Actuator
housings and covers shall be cast iron, worms shall be heat-treated carbon steel, worm wheels
shall be cast ductile iron, input shafts shall be carbon steel, shaft and worm seals shall be
BUNA-N rubber, housing to cover seals shall be impregnated cellulose fibre, bushings shall be
oil impregnated copper nickel steel alloy. The actuator shall be of sufficient capacity to operate
the damper under all conditions, and to guarantee tight close-off of the damper against all
system pressures encountered.
14.2.4 Upstream Aerosol Mixing Section
1. The combination of the aerosol injection ring and its position relative to the inlet isolation linear
damper and the design and location of the damper and the aerosol injection ring relative to the inlet
of the containment housing shall comprise an integrated system that reduces the overall unit length
as compared to a conventional housing train containment system design.
2. The aerosol injection ring located upstream of the HEPA filter shall be designed to provide uniform
aerosol challenge in accordance with IEST-RP-CC034.2 for conventional box-style, high capacity
HEPA filters and V-Bed HEPA filters when operating over the range of their rated flow rates to 20%
of their rated flow rates. The inlet linear damper blade shall function as a distribution plate to ensure
compliance with IEST-RP-CC034.2 for aerosol uniformity and/or airflow distribution per ASME
N510-2007 and/or air-aerosol mixing uniformity per ASME N510-2007, Section 9. The design and
location of the aerosol injection ring shall accommodate aerosol injection into the high velocity air
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coming through the inlet collar, and the location of the aerosol injection ring relative to the damper
shall eliminate the need for distribution plates downstream of the damper.
3. Rotating baffle plates and diffusers do not adequately represent actual operating conditions. As
such, these devices are not acceptable and shall not be offered. The manufacturer shall provide
detailed validation reports demonstrating compliance with IEST-RP-CC034.2 for aerosol uniformity
for both conventional box-style, high capacity HEPA filters and V-Bed HEPA filters when operated
at rated their flow rates and 20% of their rated flow rates.
14.2.5 Prefilter Section
1. The Prefilter section shall be a slide-in design. Access to the filters shall be from the side of the
housing.
2. Multi-wide HEPA sections shall be equipped with a filter removal rod to draw the filters to the
change-out position. The removal rod shall be operated from inside the change-out bag and shall
remove the filter by pulling against the bottom of the filter frame. There shall not be any
penetrations through the housing for operation of the removal rod. All change- out operations shall
be within the bag so there is a barrier between the worker and filter at all times.
3. The Prefilter housing section shall have a bagging ring around each access port. The bagging rings
shall have two (2) continuous ribs to secure the PVC filter change-out and scan bags. The outer
edge of the ring shall be hemmed to prevent the PVC bag from tearing. Each access port and
bagging ring shall be covered by an access door having an extruded silicone gasket that is
manually replaceable (if damaged) after the door has been removed. When closed, the door shall
not press against the bag-out port and PVC bag, thus eliminating the possibility of the bag being cut
by pressure from the door to the bag and bag-out port.
4. A minimum of four (4) feet clearance in front of each access door on the HEPA containment filter
assembly shall be reserved for filter replacement and in-place testing.
14.2.6 HEPA Filter Section
1. The HEPA filter section shall be a fluid seal design, which incorporates a knife-edge that mates into
the fluid filled perimeter channel on the face of the filter. Access to the filters shall be from the side
of the housing. There shall be a safety feature where the filter locking handle and access door shall
interface in such a manner that helps reduce the possibility of the door being closed until the filters
are correctly seated in the housing. Prior to leaving the factory, each knife-edge shall be checked
with an alignment gage to insure proper alignment with the filter. The filter sealing mechanisms
shall be replaceable and shall be operated through the change-out bag by a locking handle. The
mechanism shall exert equal force at the top and bottom edge of the filter when engaging or
disengaging the filter at the knife-edge.
2. Multi-wide HEPA sections shall be equipped with a filter removal rod to draw the filters to the
change-out position. The removal rod shall be operated from inside the change-out bag and shall
remove the filter by pulling against the bottom of the filter frame. There shall not be any
penetrations through the housing for operation of the removal rod. All change- out operations shall
be within the bag so there is a barrier between the worker and filter at all times.
3. The HEPA filter housing section shall have a bagging ring around each access port. The bagging
rings shall have two (2) continuous ribs to secure the PVC filter change-out and scan bags. The
outer edge of the ring shall be hemmed to prevent the PVC bag from tearing. Each access port and
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bagging ring shall be covered by an access door having an extruded silicone gasket that is
manually replaceable (if damaged) after the door has been removed. When closed, the door shall
not press against the bag-out port and PVC bag, thus eliminating the possibility of the bag being cut
by pressure from the door to the bag and bag-out port.
4. A minimum of four (4) feet clearance in front of each access door on the HEPA containment filter
assembly shall be reserved for filter replacement and in-place testing.
14.2.7 HEPA Filter Automated Scanning Section
1. The scan section shall be non-intrusive and shall not require the external pressure boundary of the
housing to be breached in order to conduct an in-situ scan test. The in-situ scan test housing shall
be designed to perform in-place scan testing of HEPA filter(s) by traversing the scan probes across
the full face of the filter and the perimeter filter-to-housing seal surfaces. The scanning process
shall be accomplished by mechanically positioning the probes from the exterior of the containment
system without removing an access door or access cover or otherwise breaching the exterior
pressure boundary of the housing. The probe assembly and scan testing process shall be designed
and validated to meet the intent of IEST-RP-CC001.4 for scan testing type C HEPA filters. All ports
for the scan testing process shall be 300 series stainless steel and identified with 300 series
stainless steel labels attached to the housing. All probe assembly and mechanical scan test
components of the in-situ scanning section shall be manufactured from Teflon coated aluminium,
304/304L stainless steel, polycarbonate, polyurethane, ABS or other materials that are chemically
compatible with vaporous hydrogen peroxide and paraformaldehyde decontamination agents.
2. The manufacturer shall provide detailed validation reports demonstrating the ability of the in-situ
scanning section to locate and size leaks in both high-capacity and V-Bed HEPA filters with media
leaks located in opposite corners of the filter as well as the centre of the media pack with the filters
operated at rated flow and 20% of rated flow, in both an initial orientation and rotated 180 degrees
from the initial orientation. The validation report shall also demonstrate the ability of the system to
detect gasket leaks located along both the horizontal and vertical seal surfaces.
3. Scan Probe Assembly
a. The scan probe assembly shall consist of a drive assembly installed inside of the housing and
a probe assembly coupled to the drive assembly. The drive assembly shall be designed and
installed such that it may be operated from outside of the housing, causing the probe assembly
to move linearly such that the probe transverses the entire face of the filter element which is
being scanned. The opening of the probe assembly where the sample is taken shall be
parallel to the face of the seal surface of the housing within 1 degree. The opening of the
probe assembly shall also be maintained at a minimum distance of 0.5” and a maximum
distance of 1.5” from the plane of the filter/housing seal surface and shall maintain a uniform
distance as the probe traverses across the housing with maximum variation in distance from
the plane of the filter/housing seal surface of ±0.125”.
b. The drive assembly shall be self-lubricating and not require oiling or greasing of mechanical
components in order to maintain operability over the service life of the equipment. The drive
assembly shall include non-contact end-of-traverse detection of the probe assembly and
provide feedback to the exterior of the housing to indicate end-of-traverse. The drive assembly
and associated components shall be manufactured from T-304 stainless steel, Teflon coated
aluminium, polycarbonate, polyurethane, ABS, Teflon or other materials that are chemically
compatible with vaporous hydrogen peroxide and paraformaldehyde decontamination agents.
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c. The scan probe assembly shall meet the intent of IEST-RP-CC-034.2 regarding “overlapping”
strokes when scan testing. This requirement ensures that the entire face area of the media is
scanned. The probe assembly shall be designed, installed, and operate such that the entire
face area of the filter media as well as the filter-to-housing seal is scanned in order to ensure
that there is no bypass leakage around the filter element. The scan probe assembly shall
consist of a minimum of two (2) individual scan probes for a ½-high system and four (4)
individual scan probes for a 1-high system. Each scan probe shall be connected to a quick-
release fitting installed on the front of the housing using flexible tubing and stainless steel
hardware. The scan probe assembly shall be manufactured from chemical resistant, static
dissipative polycarbonate and the flexible tubing shall be manufactured from static dissipative
polyurethane. Both shall be chemically compatible with vaporous hydrogen peroxide and
paraformaldehyde decontamination agents.
d. The quick-release fittings installed on the exterior of the housing connected to the scan probes
via the flexible tubing shall be manufactured from type 304 stainless steel and feature an
integral bubble-tight check valve with VITON seals. The fitting design shall be such that
accidental or inadvertent operation of the check valve is not possible without the use of tools,
appliances, or other hardware. Each fitting shall be uniquely color-coded and mechanically
keyed so that only one (1) mating fitting will fit each of the quick-release fittings. This ensures
that the sample lines from the control system are connected to the proper quick-release
fittings, which is critical in order to ensure accuracy of the scan test results.
e. Penetrations through the pressure boundary of the housing that may be required for the drive
assembly, scan assembly and associated hardware shall be sealed such that they meet the
pressure decay requirements of Section 3.0 during both static (non-operational) and dynamic
(scanning) states.
14.2.8 Decon Port Assemblies
1. These ports shall be installed on each filter train as shown on the drawings and shall be compatible
with the User’s decontamination equipment. Unless otherwise specified, each port shall consist of
a reinforcement plate welded to the housing side wall, 3 inch IPS Schedule 40, stainless steel pipe
nipple, 3 inch IPS stainless steel pipe flange, 3 inch IPS butterfly valve and 3 inch female IPS
aluminium hose connection with dust plug. The butterfly valve shall be wafer style, lever operated,
and shall be bubble-tight at 150 psi. It shall have a cast iron body, aluminium bronze disc, stainless
steel stem and EPDM seat.
14.3 COMMON HOUSING ACCESSORIES
14.3.1 Mounting Skid Base
1. Each filter train shall be supported by a 3 inch high by 2 inch wide, 11 gauge type 304/304L
stainless steel channel base. The channel base shall be intermittently welded to the filter train.
14.3.2 Differential Pressure Gages
2. Differential pressure gages shall be Dwyer Series 2000 Magnehelic pressure gage or equal.
Unless otherwise indicated select gage scale ranges to read at 75 percent full range (rounded up)
at the expected dirty filter pressure drop. Typical ranges follow:
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a. Filters with 25 to 30% efficiency 0 - 1.0 inches water column
based on atmospheric dust spot
test
b. Filters with 31 to 99% efficiency 0 - 3.0 inches water column
based on atmospheric dust spot
c. HEPA filters 0 - 3.0 inches water column
3. Gages shall be furnished for each filter bank, including gauges across each individual filter bank in
built-up rack assemblies, suitable for flush mounting in a panel. All sensing tubing shall be 1/4 inch
O.D. 300-series stainless steel tubing.
4. Differential Pressure Gages Ports
a. Static pressure ports shall be located on the filtration unit upstream and downstream of each
prefilter, intermediate filter and HEPA filter bank. The port connections shall be 1/4 inch 300
series stainless steel pipe half-couplings.
5. In-Line Gage HEPA Filters
a. In-line gage HEPA filter shall be Camfil Farr Gage Guardian air filter, designed to protect
diaphragm pressure indicating instrumentation (i.e. Magnehelic Gages, Photohelic Gages, etc.)
from particulate contaminants.
b. Due to life safety concerns, and considering that the integrity of the pressure boundary of these
filters is as critical as that of the containment housing, each filter shall be factory tested to
assure it is leak free and bubble-tight at a pressure of +20” w.g. by submerging the entire filter
assembly in water, pressurizing the assembly to +20” w.g. and visually inspecting for leaks.
The presence of a single bubble generated by this method constitutes a leak. Each filter shall
have a label indicating that it was leak tested. The filter media shall be hydrophobic with a
minimum efficiency of 99.9995%. The filter body shall be manufactured from T-304 stainless
steel with silicone gaskets or O-rings to ensure long service life. All wetted surfaces of the filter
shall be chemically compatible with vaporous hydrogen peroxide and paraformaldehyde
decontamination agents.
6. Gage Decontamination Ports
a. These ports shall be installed in the gage lines between the containment housing and gage(s)
as shown on the drawings and shall be compatible with commercially available vaporous
hydrogen peroxide and paraformaldehyde decontamination systems. Each port shall consist of
a stainless steel ball valve with a 3/8” female NPT connection allowing for connection to
commercially available paraformaldehyde or vaporous hydrogen peroxide decontamination
system to enable decontamination of the gage lines and in-line HEPA filter.
7. Gage Calibration Line
a. As shown on the drawings, stainless steel shutoff valves shall be provided to isolate each gage
from the process stream. A stainless steel equalization valve shall be installed between the
high and low pressure sides of each gage in such a manner that when the shutoff valves are
closed, and the equalization valve is open, the pressure across the gage equalizes for
calibration purposes without the possibility of venting to the ambient space. Shutoff and
equalization valves shall be 300 series stainless steel.
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14.3.3 Lifting Lugs
1. Lifting lugs shall be provided on the housing as required. Lifting lugs shall be fabricated from 1/4
inch plate of the same material as the housing. Lifting lugs shall have a minimum of 1-1/2 inch
diameter eyeholes and be located on the [top] [side] of the housing. Lifting lugs shall be capable of
supporting the housing (less adsorbers and filters) without causing housing deflection during
transport and installation.
2. All portions shall be free of sharp edges and burrs. Six (6) lifting lugs are required on each double
HEPA assembly, and four (4) on each single HEPA assembly.
14.3.4 Filter Change-out Tray
1. Camfil Farr shall provide a filter change-out tray to aide in filter installation and removal or in the
Bag-in/Bag-out procedure. All of the components of the change-out tray shall be type 304/304L
stainless steel. The tray shall be designed to withstand the load of (1) filter and shall be installed
over the top two door studs and use the existing hardware to be secured to the housing. One (1)
tray per filter size shall be furnished.
14.3.5 Banding Kit
1. One complete banding kit shall be provided with the filtration unit(s) equipped with a bag-in/bag-out
assembly. The banding kit shall provide a secure clamping of the bag between the housing and the
spent filtration element. Each kit shall contain a heavy duty tie-banding tool, a bag cutting tool, 1/4
inch socket wrench w/ 3 inch long extension, 1-5/16 inch hex socket, a 13 inch cinching strap with
buckle fastener, a set of ten (10) 100 pound tensile strength 14 inch long plastic ties, a set of twenty
(20) stainless steel bands, and a plastic case/apron. The banding kit and change-out bags shall be
manufactured by the same manufacturer as the housing. Additional tools required to complete the
bag-in/bag-out procedure shall also be provided.
14.4 FILTERS
14.4.1 Prefilters
1. General
a. Filter shall be Camfil Farr 30/30 or equal.
b. Air filters shall be medium efficiency ASHRAE pleated panels consisting of cotton and
synthetic media, welded wire media support grid, and beverage board enclosing frame.
c. Sizes shall be noted on drawings or other supporting materials.
2. Construction
a. Filter media shall be a cotton and synthetic blend, lofted to a uniform depth of 0.15”, and
formed into a uniform radial pleat.
b. A welded wire grid, spot-welded on one-inch centres and treated for corrosion resistance shall
be bonded to the downstream side of the media to maintain radial pleats and prevent media
oscillation.
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c. An enclosing frame of no less than 28-point high wet-strength beverage board shall provide a
rigid and durable enclosure. The frame shall be bonded to the media on all sides to prevent air
bypass. Integral diagonal support members on the air entering and air exiting side shall be
bonded to the apex of each pleat to maintain uniform pleat spacing in varying airflows.
3. Performance
a. The filter shall have a Minimum Efficiency Reporting Value of MERV 8 when evaluated under
the guidelines of ASHRAE Standard 52.2-2007. It shall also have a MERV-A of 8 when tested
per Appendix J of the same standard. The media shall maintain or increase in efficiency over
the life of the filter.
b. Initial resistance to airflow shall not exceed 0.23”, 0.31” or 0.27” w.g. at an airflow of 350, 500
or 500 fpm on 1”, 2” or 4” deep models respectively.
c. The filter shall be classified by Underwriters Laboratories as UL Class 2.
d. Manufacturer shall provide evidence of facility certification to ISO 9001:2000.
e. Manufacturer shall guarantee the integrity of the filter pack to 2.0” w.g.
4. Supporting Data
a. Provide product test report including all details as prescribed in ASHRAE Standards 52.2,
including Appendix J.
14.4.2 HEPA Filter (High Capacity)
1. General
a. Air filters shall be Camfil Farr model 12XH Absolute or engineer-approved equal. Air filters
shall be HEPA grade high-capacity air filters with waterproof micro glass fibre media, tapered
corrugated aluminium separators, urethane sealant, galvannealed 16-gauge steel enclosing
frame, and gasket. Sizes shall be as noted on drawings or other supporting materials.
b. Sizes shall be as noted on drawings or other supporting materials.
2. Construction
a. Filter media shall be one continuous pleating of microglass fibre media.
b. Pleats shall be uniformly separated by tapered corrugated aluminium separators incorporating
a hemmed edge to prevent damage to the media.
c. The media pack shall be potted into the enclosing frame through the use of a urethane sealant.
d. The enclosing frame of galvannealed 16-gauge steel shall be bonded to the media pack and
form a rugged and durable enclosure. The filter shall be assembled without the use of
fasteners to assure no frame penetrations. Overall dimensional tolerance shall be correct
within -1/8”, +0”, and square within 1/8”.
e. The filter shall be a fluid seal type and include a sealing channel on the downstream side of the
enclosing frame filled with a non-Newtonian fluid to create a positive seal between filter and
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filter housing. Filter removal clips shall be located on the upstream side of the enclosing
frame.
3. Performance
a. The filter shall have a tested efficiency of 99.99% when evaluated under the guidance of IEST
Recommended Practice. Each filter shall be labelled as to tested performance.
b. Initial resistance to airflow shall not exceed 1.35” w.g. target at rated airflow.
c. Filter shall be rated by Underwriters Laboratories as UL Class 1.
d. Manufacturer shall provide evidence of facility certification to ISO 9001:2000.
e. The filter shall be capable of withstanding 10” w.g. without failure of the media pack.
4. Supporting Documentation
a. The filter shall be labelled as to tested efficiency, rated/tested cfm, pressure drop and shall be
serialized for identification.
14.4.3 HEPA Filter (Very High Capacity)
1. General
a. Air filters shall be Camfil Farr model Filtra 2000 or engineer-approved equal. Air filters shall be
absolute grade HEPA filters consisting of pleated media packs assembled in a V-bank
configuration, polyurethane sealant, anodized aluminium enclosure and seamless sealing
gasket. Sizes shall be as noted on enclosed drawings or other supporting materials.
2. Construction
a. Filter media shall be micro fiber glass formed into minipleat pleat-in-pleat V-bank design.
b. The media packs shall be potted into the enclosing frame with fire retardant polyurethane
sealant.
c. An enclosing frame of anodized extruded aluminum shall form a rugged and durable
enclosure.
d. The filter shall be a fluid seal type and include a sealing channel on the downstream side of the
enclosing frame filled with a non-Newtonian fluid to create a positive seal between filter and
filter housing. Filter removal clips shall be located on the upstream side of the enclosing
frame.
3. Performance
a. Filter efficiency shall be 99.99% when evaluated according to the IEST Recommended
Practice. Each filter shall be labeled as to tested performance.
b. Initial resistance shall be 1.0” w.g. target at rated airflow.
c. Filter shall be qualified as UL 586 and UL 900 Class 2 per Underwriters Laboratories.
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d. Manufacturer shall provide evidence of facility certification to ISO 9001:2000.
4. Supporting Documentation
a. The filter shall be labelled as to tested efficiency, rated/tested cfm, pressure drop and shall be
serialized for identification.
14.5 EXECUTION
14.5.1 INSTALLATION
A. Install containment air filtration system in accordance with manufacturer’s instructions and
applicable sections of ASME N-509, and in accordance with the manufacturer's diagrams and
recommendations.
B. Clean all dirt, dust and debris that may be in the containment system or attached ductwork during
construction and installation.
C. Store all filters in a secure and dry storage area.
D. The HEPA filters shall be shipped separately and must be handled very carefully and stored in a
safe, dry space until ready for installation. The filter trains should be totally installed, cleaned and
operated for a minimum of one hour before any HEPA filters are installed. The HEPA filters must be
handled carefully during storage and installation.
E. Refer to details on the drawings for different configuration requirements including which assemblies
are to contain prefilters.
F. Co-ordinate location of mounting stand legs to ensure they do not conflict with light fixtures, access
covers and pipe/conduit penetration plates located in the floor.
14.5.2 WELDING
A. Welding procedures, welders, and welding operators shall be qualified in accordance with ASME
BPVC SEC IX. All welding performed shall meet the requirements specified in ASME BPVC SEC
IX and as required by ASME N509. Pressure retaining weld joints shall comply with the
requirements of ASME BPVC SEC IX.
14.5.3 FACTORY QUALITY ASSURANCE PROGRAM
A. The isolation dampers, transitions and/or plenums, housings, test sections and mounting stands
shall be manufactured and inspected under a Quality Assurance Program that meets all of the
basic requirements of ASME NQA-1, "Quality Assurance Program Requirements for Nuclear
Facilities". The manufacturer shall submit documented evidence they have been audited by
customers at least three (3) times to these requirements and successfully passed all three (3)
audits.
B. All production welds shall be visually inspected to assure that they meet the workmanship
acceptance criteria described in Sections 5 and 6 of AWS D9.1M/D9.1:2006, Specification for
Welding of Sheet Metal or ASME Boiler and Pressure Vessel Code Section IX
14.5.4 FACTORY ACCEPTANCE TESTS
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A. All acceptance tests shall be in accordance with the procedures in ASME N510 Proposed test
schedules for adjusting and balancing, housing leak and pressure, air-aerosol mixing uniformity,
damper operation and leakage, system bypass, and performance tests of systems, shall be
provided at least 2 weeks prior to the start of related testing.
B. Visual Inspection
1. Visual inspection shall be performed in accordance with ASME N510.
2. Housing Leak and Pressure Test
a. The filtration system housing shall be factory leak tested in accordance with ASME N510,
Section 6, using the pressure decay method. The housing shall be tested positively to the
design pressure of 15 inches water gauge and have a maximum leak rate of 0.0005 cfm per
cubic foot of housing volume.
3. Damper Operation and Leakage Test
a. The damper shall be tested to verify that it operates as specified. The air leakage rate through
loose isolation dampers shall be measured and recorded. The damper shall be functionally
tested as required in ASME N510.
4. System Bypass Test
a. The filtration element housing and housing seal shall be tested in accordance with ASME N510
with test blanks. The maximum housing leakage rate acceptance criteria shall be 0.0005 cfm
per cubic foot of housing volume at 10 inches water gauge pressure differential. The air that
bypasses the test blank(s) shall be measured and recorded as an air leakage rate.
14.5.5 PREPARATION FOR SHIPPING
A. The filtration system shall be mounted with protective shipping skids, crated or covered, blocked,
braced, and cushioned as necessary to prevent physical damage during shipping.
14.5.6 FIELD ACCEPTANCE TEST
A. After installation the filtration system shall be field tested for leaks using a mechanical test method.
The system shall also be tested for leaks between the filter element and its housing. Testing shall
occur after installation and shall be performed by an independent testing agency in accordance with
ASME N510. The test agency shall be certified in accordance with ASME NQA-1 or have
demonstrated previous experience with similar systems as approved by the Contracting Officer.
14.5.7 FIELD TRAINING
A. The Contractor shall conduct a training course for operating and maintenance personnel as
designated by the Contracting Officer. The manufacturer shall determine the appropriate length of
the training course. The field instruction shall cover all of the items contained in the approved
Operating and Maintenance Instructions.
15 WATER TREATMENT
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Monitoring and water treatment system for the chilled water including initial flushing, passivating and
other chemicals, materials and equipment required for a complete system.
The contract shall include the monitoring, dosing activities and all chemicals required for the 1 year free
maintenance and guarantee period for both the chilled water and hot water circuits.
16 CLOSED-DIAPHRAGM EXPANSION TANKS
Supply and install suitably sized recharged steel expansion tanks with a fixed butyl bladder to both the
chilled water and hot water pipe systems. Each tank shall have an NPT system connection and a .302”-
32 charging valve connection (standard tire valve) to facilitate the on-site charging of the tank to meet
system requirements. The tank shall be factory recharged.
17 WATER PIPING
17.1 General
Black steel piping as specified in Part 4 shall be used. Hardwood timber support blocks, of the same
outer diameter as the insulation, are to be used at each hanger or support point. The chilled water and
hot water piping shall be insulated with PIC insulation and with a vapour barrier of Foster 30 - 30 or
equivalent applied to the canvas where piping runs exposed in covered plant rooms. No vapour barrier
is required for hot water piping insulation. Where piping is exposed to outside, PIC and fibreglass
reinforced plastic shall be used. Insulation shall be painted to a colour to be specified later.
17.2 Pipe Brackets for piping hung from slab above
The piping shall be hung and supported from below with UNISTRUT type or special supports to provide
adequate support.
17.3 Automatic Air Vent-off Valves
The AC contractor shall allow for sufficient automatic air vent-off valves in the chilled water piping
system. Sufficient volume shall be provided at the air vents to trap the air. The minimum must be one
automatic air vent at each of
in the flow and return lines with rising piping;
in any other change in the level of the piping.
All the discharge points of the vents shall be piped in copper to the nearest drain.
17.4 Manual air vents
Manual air vents shall be installed at all high points of the system in parallel with the automatic air vent
system. The vents shall be made up of 6 mm dia copper pipe with an isolating ball valve, and shall be
piped to discharge in the cooling coil condensate drain pipe or the nearest foul sewer point.
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17.5 Pressure Gauges and Thermometer pockets
“Superseal” sockets, pressure and temperature gauges are to be fitted to the chilled water piping as
shown on the schematic drawings. Gauges shall be suitable for outside use.
All pressure sensor points shall have plug valves fitted to the standard U-bend pressure gauge piping or
to the sensor point to isolate the gauge or the sensor.
A set of two pairs of calibrated thermometers and pressure gauges complete with “superseal”
connectors must be provided to the engineer as part of the handover package.
17.6 Chilled water distribution network
The installation shall include controlling pressure sensors and associated network and control wiring at
the end of each loop.
18 AIR DISTRIBUTION EQUIPMENT
18.1 Ducting shall be installed in accordance with the drawings regarding routes and sizes. The duct sizes
are clear internal sizes and no allowance has been made for internal insulation where specified.
Ducting shall be manufactured and installed in accordance with SANS 1238, latest issue.
18.2 All supply air ducting shall be externally insulated where the ducting runs above the ceiling. Return air
ducting shall be externally insulated where the ducting runs in the roof space. Exhaust ducting shall not
be insulated. In specific applications where return air ducting shall be insulated, it shall be indicated on
the drawings.
18.3 Return air grilles are to be of the Europair RA or equivalent type with manually opposed blade dampers.
18.5 Constant air volume supply are grilles shall be white powder coated and of the Trox type as indicated by
the schedules. The variable air volume system shall be Rickard variable geometry wall mounted type,
with reheaters
18.6 Where flexible ducting joins on to sheet metal, the flex shall be connected to the spigot with a
galvanised clamp and the joints shall be sealed with foil backed adhesive tape.
18.7 All ducting shall be painted to a colour to be specified at a later stage.
19 INSTRUMENTATION
19.1 Pressure Gauges
Pressure gauge points with shut-off valves are to be fitted to the chilled water piping at the inlet and
outlet of fan coil units, chillers, strainers and circulation pumps as shown on the pipe schematic.
19.2 Thermometer Pockets and thermometers.
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Thermometer pockets are required on the entering and leaving pipes of the fresh air handling unit. This
is not required on fan coil units.
Dial gauge thermometers shall be installed at the inlet and outlet of the outside air handling unit and the
chiller. The thermometers shall be installed between 1000 mm and 1800 mm AFFL. If it is not practical
to install a thermometer between these limits, a circular dial type thermometer shall be installed with the
dial between the stated limits. The thermometer shall have a minimum of 100 mm diameter faceplate.
20 ELECTRICAL INSTALLATION
20.1 General
The contractor is responsible for the design and supply of the AC control and electrical panels. The field
wiring associated with the system forms part of the scope of work.
The AC contractor shall supply any local isolators (or key operated lock-out switches) where the item of
equipment is not visible from the switchboard.
The wiring shall conform to the Codes of Practice. The contractor shall supply any local isolators (or
key operated lockout switches) where the item of equipment is not visible from the switchboard.
20.2 Conduiting and Chasing of Walls
The contractor shall be responsible for all bosal conduiting, Ega tubing or trunking, cable trays etc.
required by him for his electrics in plant areas, storerooms, etc.
Cables in plant areas, storerooms etc. may run exposed, surface mounted or on cable trays (depending
on the application, support required etc.)
Where controllers are to be wall mounted in user areas, all conduiting and terminal boxes will be
supplied by the contractor but built-in by the principal contractor.
20.3 Wiring Diagrams
Wiring diagrams are to be submitted to the Engineer for scrutiny before commencement of the
manufacture of the switchboards or the installation of the field wiring on site. On completion of the
installation, the drawings are to be modified to reflect the as-built status. These diagrams will form part
of the Operating and Maintenance Manual for the project.
20.4 Switchboard Diagrams
The as-built circuit diagrams of the AC switchboards shall be framed and mounted in the associated AC
Plant room at least 1 week prior to contract completion. The wiring diagrams shall be laminated and
hinged into the distribution board.
20.5 Alarms
Provision shall be made for the shutdown of all air handling plant, including custom fan-coil units on
receipt of a fire signal from the fire detection system. The connection shall be a hard-wired connection
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into the electrical board and provision shall be made for relays and contactors in the board that can take
a 12V fire signal from the fire detection system.
20.6 Location of Electrical Panels
20.6.1 Air handling plant electrical panels
The electrical panel shall be provided with the following:
The electrical panel shall be weatherproof, made of stainless steel and mounted against the building
wall as indicated on the drawings. The DB will serve the following equipment:
Sub electrical distribution board at the chiller plant
Control system
All supply and exhaust air handling units
The electrical sub contractor will provide the following to the vicinity of this location. The AC electrical
sub contractor shall terminate these cables to the main panel.
25% spare capacity shall be allowed for future use
A UPS shall be provided as part of this project to protect the control system and to provide power to the
control systems for a minimum of 10 minutes.
21 CONTROL SYSTEM
21.1 General description of the controls
Direct Digital Control system
The Schneider Electric Controls system, or approved alternative, is specified for this project. The air
handling unit will have a dedicated direct digital control system which will control the various elements
complete with mimic control panel. System to accommodate different user system access levels with
defined privileges (e.g. to make parameter or setting changes, acknowledge/silence alarms etc.). Logs
of user activity to be stored on the BMS.
The mimic screen background to be the lab floor plan drawing with room parameters depicted for
respective room spaces.
The main control system shall be located at the air handling plant.
The points list shall be compiled by the controls specialist and submitted to the Consulting Engineer for
scrutiny before order/manufacture.
Start-up procedure
This sequence is automated, but initiated manually.
1. Screen is activated and PIN entered.
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2. Start sequence activated with start button.
3. Graphics change to screen indicating the room parameters (temperature, airflow rate, humidity,
relative to ambient pressures, filter status, UPS health etc.).
4. Exhaust fans start up and ramps to 70 % speed. When the exhaust flow switches activates, the
exhaust bubble free damper opens.
5. Supply air fan ramps up to 60% speed. When the flow switch on the supply air activates, the
supply bubble free damper opens.
6. The fans are left running on the fixed speed above for 180 seconds and then switches to
automatic control.
7. The system shall then adjust the airflow to 6 air changes per hour automatically.
8. When the target air change rate is reached, the chiller and humidity control systems are
activated, the controls system automatic adjusts the set points to match the outside ambient
conditions to limit the energy consumption, and then user control interface becomes live.
9. The user can then set the required conditions and lock the controls to prevent tampering. The
screen will show live parameters.
Normal Shut down procedure
This procedure is for normal shut down, say for cleaning or maintenance. This sequence is automated,
but initiated manually.
1. Temperature and humidity controls shuts down
2. Supply air fan shuts down
3. Dampers close
4. Exhaust damper close
5. Exhaust fan shuts down
Emergency shut down procedure
This sequence will be initiated automatically when the integrity of the laboratory is at risk, such as,
supply fan failure, exhaust fan failure, imminent UPS failure, generator failing to start, HEPA filters dirty
or punctured, etc.
1. Supply air fan and dampers shuts immediately
2. Exhaust fan shuts down
3. Exhaust damper closes when the pressure is below 15 Pa.
The contractor shall ensure that the inertia of the exhaust air fan is greater than that of the
supply air fan. In addition, the “brake” function on the VSD for the supply air fan shall be
activated.
Fire signal shut down
All equipment, except the exhaust air fan, immediately shuts down.
21.2 Air Handling unit control
Air handling units
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Each air handling unit shall be controlled via the applicable Schneider Electric controller. A
temperature/humidity sensor located in the return from the room shall control the space temperature. If
the return air temperature is lower than the set point, the controller shall adjust the position of the chilled
water control valve to allow less chilled water through the valve. If the return temperature is too high,
the opposite shall take place.
Should the relative humidity be too high, the cooling valve shall be forced to the fully open position and
the supply air temperature be controlled by the electric heater. The heater shall be control by a current
valve complete with PID control algorithm.
Should the humidity be too low, a steam humidifier with PID controls system shall be activated.
The stopping and starting of the fan shall be integrated with the operation of the air handling unit and be
via a time clock in the Schneider Electric control system.
21.3 Pumps
The pump shall be control via the chiller on-board control system.
The stopping and starting of the pumps shall be integrated with the operation of the chiller.
21.4 Control Equipment
Chilled water valves and actuators
The size and chilled water flow shall be as indicated in the relevant schedule. The chilled water valve
shall be selected to have a pressure drop of approximately 30kPA in the fully open position with the
design water flow.
Valves up to and including 50 mm dia. shall be screwed and valves 65 mm dia. and larger shall be
flanged. The valves shall have an equal percentage flow characteristic. The valve body shall be cast
iron and all internals stainless steel.
The valve actuator shall be able to be removed from the valve body for service purposes. The valve
actuator shall be fitted with an ‘Auto/Manual’ switch that will enable an operator to manually adjust or
test the control valve. The valve/actuator assembly shall be fitted with a position indicator to indicate the
position of the valve. To provide a ‘fail safe’ mode of operation the valves shall be fitted with a spring to
enable the valve to close when control power to the unit is interrupted. The valves shall be able to
operate and close with a differential pressure of up to 200kPa.
Variable Speed Drives
The variable speed drives shall either be an OEM supply or another make that has been used and
designed for air conditioning applications such as Danfoss. The units shall be state of the art and
designed for air conditioning use. The units shall have a high tolerance to electromagnetic disturbances;
have an in-built AC choke and RFI filter. The unit shall be assembled in a metal enclosure, have its own
ventilation system and fan, and be wall mounted.
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The unit shall have a user interface consisting of an alphanumeric display panel, navigation and
programming buttons, and an emergency stop button. Active faults as well as a fault history shall be
maintained in the unit’s memory.
The unit shall be able to handle the nominal supply voltage of 400V AC ± 35%. The unit shall be able
to handle positive and negative ‘spikes’ without tripping and the necessity for manual ‘reset’ of the unit.
The unit shall be fully compatible with the BMS and be able to communicate and pass and receive
information freely.
22 PAINTING AND PLANT IDENTIFICATION
The contractor shall be responsible for the painting of:
1 All brackets and fixings prior to erection
2 All metalwork which is not otherwise protected against corrosion
3 Painting of the chilled water piping in the AHU plant rooms
4 Painting of direction arrows on the chilled water piping in the plant room
5 Painting a matt black finish to the inside surfaces of the sheet metal ducting which will be visible
through grilles
6 Labeling all plant to correspond with the plant identification on the switchboards
7 Painting the inside surfaces of the drip trays of the main AHU cooling coils and chilled water pump
with a bituminous paint
8 Touch up paint with cold galvanizing paint of all galvanized surfaces cut on site
9 Paint all brackets (not hot-dipped galvanized after construction) inside the
Building
23 TESTING AND COMMISSIONING
The system will be subjected to a rigorous testing regime with the intent of ensuring that the users of the
facility will be safe at all times. The testing, commissioning and handover of the system will comprise of,
but not be limited to the following items. Each of the sections are to be accepted by the client and/or his
representatives before the testing can proceed to the next section. Should any of the sections fail, the
contractor shall be required to restart the entire testing, once the defect is rectified.
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Visual inspections
This section relates to the quality of the installation.
The client and the Consulting Engineer shall inspect the system and check general items, such as
condensate drains, fan belts, mounting of the equipment, whether wall penetrations were sealed etc.
Systems configuration inspection
This section relates to the safety equipment as specified.
a. Are the backdraft dampers installed correctly?
b. Are the filters installed correctly?
c. Are the decontamination loops installed correctly?
d. Are the air tight dampers installed correctly?
e. Are the alarms, visual and audible installed correctly?
f. Any other items relating to the safety of the lab.
Integrity test
This section relates to the integrity of the containment barrier of the laboratory. The test procedure is
described elsewhere in the specification
a. Lab envelope pressure test to verify the degree of tightness
b. Supply air ducting pressure test
c. Exhaust air pressure test
d. Filter certification
Start-up test
The start-up sequence will be initiated as described, and monitored to by the client and consulting
engineer on both the control system interface and analogue monitoring equipment (thermometer,
Magnehelic differential pressure gauge and flow measurement device, such as a pitot tube).The
aforementioned equipment shall be supplied by the contractor and be accompanied by a recent
calibration certificate.
Operational test
This section relates to testing the room conditions at various set points. These conditions will be
validated and documented.
a. Directional airflow (Smoke test) at various air flow rates.
b. Stability of temperature and humidity at various air flow rates by logging the conditions for an
agreed period.
c. Ease of operation
Manual/Normal shut-down procedures
In this section, a manual shut down will be initiated and the system monitored by the client to verify a
safe shut-down procedure.
Emergency shutdown procedures
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In this section, each of the following events shall be simulated, and the client and consulting engineer
will then observe whether a safe shutdown procedure is followed.
a. Supply air fan failure
b. Exhaust air fan failure
c. Power failure
d. Generator failure to start
e. Imminent UPS failure
f. Filters blocked
g. Filters punctured
The contractor shall note that the list above is not necessarily exhaustive, and additional tests may be
required by the Client and his representatives. These tests shall be carried out at no additional cost to
the Client.
24 COMPLETION OF INSTALLATION
Before the commencement of any tests or commissioning procedures, the Contractor is to ensure that
all nuts and bolts are securely fastened, and that paintwork on all items supplied has been touched up
where damage has occurred.
25 COMMISIONING, TESTING, ACCEPTANCE AND HANDOVER OF THE SYSTEM
The quality assurance and quality control during the installation shall be carried out as per the supplier’s
prescribed methodology.
Contractors shall note that the installation shall not be accepted by the Client if the installation was not
installed as per the supplier’s installation manual, and certified as such in writing by the supplier. Copies
of this certificate shall be presented to the Consulting Engineer before commissioning commences.
Contractors shall further note that the system shall not be accepted by the Client if the system was not
commissioned as per the supplier’s commissioning manual, and certified as such in writing by the
supplier. Copies of this certificate shall be presented to the Consulting Engineer upon completion of
commissioning.
When the testing has been carried out in full, and to the satisfaction of both the Client and Consulting
Engineer, a set of documents shall be compiled and presented to the Engineer. This set shall include
the following:
1. Complete systems description
2. CAD copy of all drawings marked up “as built”.
3. Description of the controls methodology
4. Completed set of workshop drawings, including control points lists
5. Certificates
i. Certificates of compliance for the electrical installation
ii. DOP test certificate
iii. Pressure testing certificate
iv. Certificate signed by the Client and his representatives for each of the tests sections
listed above.
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6. Completed set of test and commissioning sheets.
7. Set of schematic wiring and function diagrams.
8. File of distribution board legends.
9. Operating and maintenance instructions on all electrical equipment.
10. Guarantees and manufacturers literature of all installed equipment
11. Maintenance roster for the free guarantee period
12. Emergency contact details
26 AS BUILT DRAWINGS
The Contractor shall submit to the Engineer a complete set of accurately marked-up, cad drawings of all
services installed at completion.
The drawings shall be on cad, a hard copy of each drawing shall be submitted as well as a compact
disk containing relevant drawing titles.
27 DETAIL ENGINEERING AND WORKSHOP DRAWINGS
Included in this contract is the detailed engineering and submission to the engineer by the air
conditioning and ventilation systems contractor of the following:
Detailed engineering of pipe reticulation systems
Calculation of refrigerant pipe and pipe system component friction losses
Economical sizing and selection of piping
Engineering of pipe reticulation routes and falls to ensure low noise and effective oil return
Detailed engineering of duct reticulation systems
Calculation of duct system friction losses and sizing
Detailed engineering of plant room layouts including weights
Calculations of fan and attenuator sizes to comply with noise criteria and the principles of
economic selection of motors.
Preparation of detailed workshop drawings in AutoCAD format
28 MINIMUM REQUIREMENTS FOR ONSITE TECHNICIANS
All tenderers shall as part of the returnable documents provide details of the following, over and above
the mandatory documentation as per the National Treasury procurement procedure.
Provide details of registered Gas Practitioners with valid SAQCC registration details
permanently employed within your organisation. Provide proof by way of name and registration
number of each Practitioner.
Provide details and registration number of the Electrical Wireman in your organisation licenced
to issue an electrical COC for HVAC installations.
Provide details of HVAC NQF level training undertaken in your organisation. (Provide details of
Trainee name, modules completed (for which Trainee has been found to be competent), and
organisation undertaking the training).
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Provide proof of minimum 5 successful previous installations of similar nature and magnitude,
for the principal contractor and each of his subcontractors, by means commissioning certificate
as issued by the supplier and traceable references for each project.
Provide proof that company is based no more than 100 km from the site by means of municipal
utility bills not older than three months
Provide details of qualified refrigeration technicians to be dedicated to the project
Provide details of staff members with B.Eng., B.Sc. (Eng.), Beach. Eng. or N.DIP from
reputable tertiary institutes.
PART 6
SCHEDULES
1.0 SCHEDULE OF DRAWINGS
1. C2206 AC1 002 rev 2
2
2. SCHEDULE OF CONTROL POINTS
AI DI AO DO
Velocity sensor 1
VSD control supply air 1 1
Chiller enable 1
Spring return dampers 2
Differential pressure sensor 4
Differential sensor supply air 1
VSD control exhaust air 1 1
Supply air 1
Exhaust air 1
Current Valve Control 1 1
Humidity sensor duct 1
Humidifier 1
Cooling valve control 1
Filter pressures 5
Alarm strobe output 1
spare 6 4 3 3
TOTAL 20 4 8 10
3
3. SCHEDULE OF AIR HANDLING UNITS
INFORMATION REQUIRED DATA OF NEW EQUIPMENT DATA OF
EQUIPMENT
OFFERED
1 GENERAL
1,1 Position As shown
1,2 Code
1,3 Type of System Variable Volume
1,4 Maximum Air Flow (m3/s) 0,35
1,5 Manufacturer Air Options or similar
1,6 Model No.
1,7 External Air resistance (Pa) 120
1,8 No. of 1
2 FILTER
2,1 Type Primary WP-77 Fibatron washable
2,2 Type Secondary Bag type
3 COOLING COIL
3,1 Cooling capacity 24.7
(kW total)
3,2 Sensible coil load (kW) 13.7
3,3 On Coil Temperature (°C) 30.0 / 20.0 DB/WB
3,4 Off Coil Temperature (°C) 2.2 / 2 DB/WB
3,5 Water Supply / Return (°C) 0 / 5
3,6 Water Resistance (kPa) 30 Maximum
3,7 Air Resistance (Pa) 50 Maximum
3,8 Air Speed (m/s) 2,5
3,9 Water Flow (l/s) 1.19
3,1 Distance Between Fins (mm) 2,5
3,1 Material Aluminium fins+ copper coil
3,1 Rows 3
3,1 Fins/25mm -
4
INFORMATION REQUIRED DATA OF NEW EQUIPMENT DATA OF
EQUIPMENT
OFFERED
4 HEATING COIL
10.9
4,1 Air Supply (ºC)
4,2 Air Return (ºC) 1.1
4,3 Capacity (kW) 12.5
4,4 water flow (l/s) n/a
5 FAN
5,1 Type of Fan BCC
5,2 External static Pressure (Pa) 100
5,3 Fan Efficiency (%)
5,4 Fan Power Supply (kW)
5,5 Outlet Air Speed
5,6 Fan R.P.M.
5,7 Manufacturer
5,8 Model No.
5,9 Speed Control yes
6 POWER
6,1 Fan Power (kW)
6,2 Fan Motor Capacity (kW)
6,3 Fan Motor R.P.M. 1400
6,4 Power Supply V/Phase/Hz 400/3/50
5
4. SCHEDULE OF EXHAUST FANS
INFORMATION
REQUIRED
DATA OF
EQUIPMENT
DATA OF
EQUIPMENT
OFFERED
1 GENERAL
1,1 Designation As shown
1,2 System Filtered extraction
system
1,3 Type of System Variable volume
1,4 Manufacturer Donkin or similar
1,5 Country of origin RSA
1,6 Model No.
1,7 No. of 1
2 TECHNICAL
2,1 Type BCC
2,2 Maximum Air Flow
(l/s)
420
2,3 Total Static pressure
(Pa)
1000
2,4 Efficiency (%) 52%
2,5 Fan RPM 1440
2,6 Sound (dBA) 50
3 POWER
3,1 Fan (kW) / Motor
(kW)
3,2 Speed control N/A
3,3 Power 400/50/3
4 SOUND
ATTENUATOR
4,1 Manufacturer Donkin
4,2 Model No. Silax
4,3 Dimensions D
4,4 Length mm
4,5 No. off 2
6
5. SCHEDULE OF AIR COOLED CHILLERS
INFORMATION REQUIRED DATA OF EQUIPMENT DATA OF
EQUIPMENT
OFFERED
1 GENERAL
1,1 Type of chiller Ducted Air- Cooled Scroll
1,2 Number of 1
1,3 Manufacturer Carrier or Approved alternative
1,4 Country of origin France
1,5 Size and model No. 30RBY033CF
1,6 Refrigerant R 410A
1,7 Design Capacity each 26.8 kw
2 EVAPORATOR
2,1 Refrigerant 20 % Ethylene Glycol
2,2 Inlet/Outlet water temperature
(°C)
+5.0°C / 0°C
2,3 Flow rate (l/s) 1.35
2,4 Fouling factor (m2kW) 0.0176
2,5 Pressure drop (kPa) 30 max
2,6 Number of circuits 1
2,7 Number of Compressors 2
3 Condenser
3,1 Type Air-cooled
3,2 Ambient temperature (°C) 30
3,3 Condenser fin material Aluminium fins
3,4 Condenser ambient range Standard Ambient
3,5 Fan power Motor
3,6 Number of fans
3,7 Corrosion Protection Yes
7
INFORMATION REQUIRED DATA OF EQUIPMENT DATA OF
EQUIPMENT
OFFERED
4 COMPRESSOR
4,1 Type Hermitically sealed scroll
4,2 RPM
4,3 Capacity steps 1
4,4
5 MOTOR
5,1 Type
5,2 Starter Wye-delta closed Transition
5,3 Max (kW)
5,4 Electrical power 400/50/3
5,5 Running current (A)
5,6 Starting current (A)
6 PUMP
6,1 Water flow rate As per chiller evaporator data
6,2 External static pressure To be calculated
6,3 Motor To be calculated
TENDER PRICE BREAKDOWN SCHEDULE
SCHEDULE NO.1 : PRELIMINARY AND GENERAL COSTS
(Note : These prices shall be firm and not subject to price adjustment)
Item Description Unit QTY Supply Rate Install Rate Amount
1,1 SITE ESTABLISHMENT
1 Camp and fencing sum 1
2 Office sum 1
3 Office Equipment sum 1
4 Store sum 1
5 Workshop sum 1
6 Other sum 1
1,2 ADMINISTRATIVE
1 Site personnel sum 1
2 Supervisory staff sum 1
3 Guards sum 1
4 Transport sum 1
5 Insurance sum 1
6 Cost of Guarantee sum 1
7 Financing of Retention sum 1
8 Running costs e.g. telephone, electricity,
9 cleaning, services, printing, stationery, etc. sum 1
1,3 GENERAL COSTS
1 Allow an amount if required for expenses incurred
to tender. sum 1
2 Loading and off loading of material and equipment sum 1
3 Setting out of Works. sum 1
4 Cleaning of site upon completion of Contract. sum 1
5 Critical Path/Schedule. sum 1
6 Issuing Cadded Workshop drawings sum 1
7 Issuing 4 sets of "As-built" drawings and operational manuals including CD sum 1
8 Test and commissioning of complete Works. sum 1
9 Inspection and handing over. sum 1
1,4 COMPLIANCE
1 Allow for complying with the conditions & requirements of
tendering & contract conditions sum 1
Total for Schedule No. 1 Carried forward to summary page R
SCHEDULE NUMBER 2: BUILDERS WORKS AND SUPPLY OF LABORATORY EQUIPMENT
(Note : These prices shall be firm and not subject to price adjustment)
Item Description Unit QTY Supply Rate Install Rate Amount
2,1 Supply and installation of cold room panels, and alterations to the layout of the existing
facility, in order to create ante rooms and plant area
2,2 Sealing of all penetrations, joints, frames etc. with a medical grade sealant to ensure an airtight room sum 1
2,3 Alterations to the ceiling structure of existing lab to create ceiling space for plant area sum 1
2,4 New plinth for the chiller sum 1
2,5 New plinth for the generator sum 1
2,6 Supply, installation and commissioning of a new Class II biosafety cabinet for installation in the
dirty ante room. Refer to the schedules. sum 1
2,7 Supply and installation of a portable effluent treatment device for the laboratory. Refer to the
schedules sum 1
2,8 All penetrations and making good of all trades sum 1
2,9 Provision of a drain point for the air conditioning system sum 1
2,10 Provision of a 15mm potable water connection to the chiller plant area. sum 1
2,11 Co-ordination with other services and principal contractor to ensure the successful completion of
the project. sum 1
Total for Schedule No. 2 Carried forward to summary page R -
SCHEDULE NO 3: SUPPLY, INSTALLATION AND COMMISSIONING OF MECHANICAL SYSTEMS
Item Description Unit QTY Supply Rate Install Rate Amount
1 Supply and installation of a low noise, air cooled chiller to provide chilled water to the air handling
unit.
2 Supply and installation of a chilled water circulation pump to the chiller plant. sum 1
3 Supply and installation of one minimum 500 L capacity insulated chilled water buffer tank for chiller
plant. sum 1
4 Supply and installation of all chilled water piping and ancillaries as indicated on the concept design
drawings. sum 1
5Supply and installation of ducting and diffusers as indicated on the concept design drawings.
sum 1
6Supply and installation of exhaust fan-filter system as indicated on the concept design drawings.
sum 1
7 Supply and installation air-handling unit with electric heating and chilled water cooling coils as
indicated on the on the concept design drawings. sum 1
8Supply and installation of condensate drains from all condensate drain pans to the nearest drain
point. It will be the responsibility of the Contractor to ensure that the condensate drains are
individually reticulated to the nearest foul water drain. sum 1
9 Connection of the chilled water piping to the make-up water point provided by the building
subcontractor. sum 1
10
The electrical scope of works pertaining the mechanical installation comprise of the necessary
main and electrical sub-panels, motor control centre, switchgear, contactors, isolators, starters,
motor protection units, speed controllers, etc, including all the necessary field wiring and
connections to the various systems unless otherwise indicated.
sum 1
11 A central master control system shall be located in close proximity of the HVAC plant. A remote
control panel shall be located at the entrance to the new facility. Refer to the concept design
drawings and detail specification. sum 1
12 Testing, commissioning, certification and ensuring the sign off by the Client and his representatives
of all systems. sum 1
13 Coordination of all services, including but not limited to electrical and builder’s work, including the
timeous provision of workshop drawings and relevant details. sum 1
14
Provision for three copies of operating and maintenance manuals including installation drawings.
Installation drawings shall also be available in AutoCad format. The contents of the manual shall
be as specified in the Standard Specifications. NOTE: The installation shall not be considered
practically complete or complete for beneficial use until the systems have been properly
commissioned and approved and O&M manuals have been submitted that incorporates all the
commissioning figures and data. 5% of the tender amount shall not be certified until the approved
O&M manuals have been received.
sum 1
15 The 12 months guarantee and maintenance of the installed systems. sum 1
16 Training of users and maintenance staff. sum 1
17 Automatic water treatment system for the chilled water systems. sum 1
18 A provisional amount has been included in the tender breakdown for scope of work not yet
defined. sum 1
Total for Schedule No. 3 Carried forward to summary page R -
SCHEDULE NO.4 : SUPPLY AND INSTALLATION OF ELECTRICAL SYSTEMS
Description Unit QTY Supply Rate Install Rate Amount
1 TOTAL FOR THE ELECTRICAL BILL OF QUANTITIES CARRIED FORWARD SUM 1
2 TOTAL FOR GENERATOR INSTALLATION BILL OF QUANTITIES CARRIED
FORWARD
3 TOTAL FOR UPS INSTALLATION BILL OF QUANTITIES CARRIED FORWARD
4 TOTAL FOR ACCESS CONTROL INSTALLATION BILL OF QUANTITIES CARRIED
FORWARD
Total for Schedule No. 4 Carried forward to summary page R -
Item Description Sub-Total
TOTAL FOR SCHEDULE NO. 1
TOTAL FOR SCHEDULE NO. 2
TOTAL FOR SCHEDULE NO. 3
TOTAL FOR SCHEDULE NO. 4
TOTAL FOR SCHEDULES (excl. VAT)
Item Description Unit Rate Amount Sub-Total
CONSTRUCTION OF A BSL3 FACILITY AT NIOH, BRAAMFONTEIN
A Schedules No. 1 TO 4 -
Subtotal -
Provisional Amounts for :
B Provisional Amount for Unforseen work 200 000,00
C Security 200 000,00
D -
E -
Subtotal for B+C+D+E 400 000,00
TOTAL NET CONTRACT SUM (excl vat)
1 Above amounts to be carried forward toForm of Tender
contained in this document.
2 All the rates in this document must be supplied.
3 Above amounts to exclude VAT.
SUMMARY OF SCHEDULES
TENDER SUMMARY
PART 2 ELECTRICAL PROJECT SPECIFICATION
PART 2 ELECTRICAL PROJECT SPECIFICATION INDEX ITEM DESCRIPTION PAGE NO.
1.0 SITE 3
2.0 VISIT TO SITE 3
3.0 BILLS OF QUANTITIES 3
4.0 SCOPE OF CONTRACT 3
5.0 OTHER CONTRACTORS AND SPECIALISTS 3
6.0 COMPLIANCE WITH REGULATIONS 4
7.0 PROGRAMME 4
8.0 WORKMANSHIP 4
9.0 QUALITY OF MATERIAL 5
10.0 BUILDERS WORK 5
11.0 ELECTRICAL SUPPLY 5
12.0 LOW-VOLTAGE CABLES 5
13.0 CABLE TRAYS, LADDERS AND WIRE MESH TRAYS 6
14.0 DISTRIBUTION BOARDS 7
15.0 WIRING CHANNEL INSTALLATION 13
16.0 POWER SKIRTING 14
17.0 CONDUIT INSTALLATION 15
18.0 WIRING 18
19.0 SWITCHES AND SOCKET OUTLETS 20
20.0 LIGHT FITTINGS 22
21.0 AIRCONDITIONING OUTLETS 23
22.0 FIXING OF MATERIALS 23
23.0 CONNECTIONS 24
24.0 DATA/TELEPHONE, FIRE DETECTION & ACCESS CONTROLINSTALLATION 25
25.0 EARTHING 25
26.0 PHOTOELECTRIC SWITCHES 26
27.0 ACCESS CONTROL 27
28.0 INSPECTION AND TESTING 27
29.0 TESTING AND COMMISSIONING DOCUMENTATION 27
30.0 COMPLETION OF INSTALLATION 28
31.0 AS BUILT DRAWINGS 28
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PROJECT SPECIFICATION
1.0 SITE
The site is located on the corner of 25 Hospital street, Braamfontein,Johannesburg. 2.0 VISIT TO SITE
Tenderers shall acquaint themselves with local site conditions such as access to the site, size and type of site, type of ground, supply of labour, workshop space, transport, loading and unloading facilities, scaffolding, tackle and tools needed for the erection of the installation. Additional claims by the Sub-Contractor, which may arise from ignorance of the site conditions, will not be considered and Tenderers are required to visit and inspect the site in the company of the engineer for a formal site visit. Refer to the principal contract for details regarding the date and time of the site visit.
3.0 BILLS OF QUANTITIES
Included in this document is a bill of quantities for every type of operation which may occur during the execution of the electrical installation. As part of their submission, tenderers must complete this bills of quantities.
The rates supplied in this bill shall be fixed for the duration of the contract and be nett, excluding VAT. The rates for the supply and installation shall be inclusive of small items, such as screws, washers, etc.
These rates shall be used in the adjudication of the electrical tenders.
4.0 SCOPE OF CONTRACT
The following scope of work is included in this contract:
a) Supply and Install new electrical circuits, light fittings, SSO’s, power skirting, trunking, wireways and data outlets to accommodate the new laboratory installation and building layout. (All positions and outlets to be marked and submitted on the electrical layout drawing)
b) Termination of new wiring on circuit breakers in all panels. c) Supply new DB as per schematic C2206 E1 SLD 002 R1, connect circuits, label all circuits as well
providing a laminated legend card. d) Provide a SSO control panel complete with indication lamps, power supply and switch gear, wired
to control each SSO in Laboratory separately from hallway. e) Install new specified fluorescent vapourproof light fittings controlled from a single 3 lever one way
light switch. f) Supply and install cable trays, wiring channels, conduits, wiring, power skirting, small power outlets
and lighting forming part of the electrical installation. g) Make provision for access control services, install all conduits and draw boxes as per drawings,
specialist to install equipment. h) Supply and commission new outdoor 120kVA generator, complete with plinth, canopy, battery est.
as specified with cable terminations on minisub, changeover and DB-LAB. i) Supply and install 160A circuit breaker at minisub and coordinate shut-down with LAB
management. j) Supply and commission new 100kVA UPS complete with 30min back-up supply and alarm cable
installation as specified with cable terminations on DB-LAB. k) All conduiting, trunking or skirting should be silicon sealed to ensure no air contact with the outside. l) Testing, commissioning and handover of the system to the complete satisfaction of the CLIENT.
Handover will include the presentation to the ENGINEER of two complete sets of drawings
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reflecting accurately and in detail the "as-built" state of the electrical installation. Drawings will be bound in separate manuals each, which will also contain all technical information of luminaires, power equipment and certificates required by the ENGINEER.
5.0 OTHER CONTRACTORS AND SPECIALISTS
The appointed Electrical Contractor shall be a selected Sub-contractor to the Main/Principal Contractor. The Main Contractor shall be responsible for the overall programming and co-ordination of all Sub-contractors on site. This shall in no way exonerate the Electrical Sub-Contractor from his obligations in terms of this contract.
6.0 COMPLIANCE WITH REGULATIONS
The installation shall be erected and carried out in compliance with:
a) The local Municipal by-laws and Regulations as well as the regulations of the local Supply Authority.
b) The local Fire Regulations.
c) The Standard Regulations of any Government Department or public service where applicable.
d) Safety arrangements and procedural compliance with the Occupational Health and Safety act; Act 85 of 1993 as amended incorporating SANS 10142.
The Sub-Contractor shall at his cost issue all drawings and notices in respect of modification of the installation to the local authorities, and shall indemnify and exempt the CLIENT from all losses, costs or expenditure which may arise as a result of the Contractor's negligence to comply with the requirements of the regulations stipulated above. No work, by the Sub-Contractor, shall commence prior to the approvals by the local authority of the relevant drawings or applications to perform work.
It shall be assumed that the Sub-Contractor is conversant with the abovementioned requirements. Should any requirement, by-law or regulation, which contradicts the requirements of this Document, apply or become applicable during erection of the installation, such requirement, by-law or regulation shall overrule this Document and the Sub-Contractor shall immediately inform the CLIENT of such a contradiction. Under no circumstances shall the Sub-Contractor carry out variations to the installation in terms of such contradictions without obtaining the written permission to do so from the CLIENT.
7.0 PROGRAMME
The Tenderers’ price should be based on the following programme:
The building project construction period shall extend over a period of approximately four months. The Sub-Contractor will perform his installation in accordance with the Main Contractor’s overall construction Programme.
8.0 WORKMANSHIP
The Sub-Contractor shall employ only competent artisans to perform construction and installation work on the site.
The Sub-Contract shall be executed with the best workmanship in a workmanlike manner to the satisfaction of the ENGINEER. Should any workmanship not be to the satisfaction of the ENGINEER it shall be rectified at the cost of the Sub-Contractor.
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The Sub-Contractor shall remain responsible for the correct and complete delivery of the installation. Inspection by the ENGINEER shall not release the Sub-Contractor from his responsibility.
9.0 QUALITY OF MATERIAL
Only material of high quality and suitable for the climatic conditions of the site shall be used and shall be subject to approval by the ENGINEER. All material shall conform in respect of quality, manufacture, tests and performance, with the requirements of the SANS or where no such standards exist, conform to the appropriate current Specification of the British Standards Institution. Materials manufactured in South Africa shall as far as possible be used and where applicable shall bear the SABS mark. Imported materials shall comply with the requirements of the appropriate B.S. or I.E.C. specification. All materials shall be suitable for the conditions under which the materials are installed and used. Should the materials or components not be suitable for temporary use under site conditions, the Sub-Contractor shall at his own cost provide suitable protection until these unfavourable site conditions cease to exist.
10.0 BUILDERS’ WORK
The Sub-Contractor will provide, within the scope of his supply and installation undertaking, for all chasing required for the flush installation of conduit, conduit fittings, outlet boxes or trays but the Main Contractor will repair all chases and shall re-instate structural surfaces to the final finishes required. The Main Contractor shall also provide the following: a) The removal and replacement of ceiling tiles, where required, to allow the sub-Contractor
access to perform work in ceiling spaces. b) Cutting holes in ceiling tiles for installation of luminaires.
The Sub-Contractor shall liaise closely with the Contractor in the above regard and the Sub-Contractor shall remain responsible for the correct and accurate location of manholes, sleeves, and penetrations.
11.0 ELECTRICAL SUPPLY
The sub-contractor will be required to install and supply a new 160A circuit breaker in the existing minisub and coordinate the shut-down process.
12.0 LOW-VOLTAGE CABLES
The Sub-contractor shall supply and install all the low voltage cables as indicated on the drawings and cable schedules.
The low voltage cables shall be of the 600/1000 volt PVC insulated, steel wire armoured copper cable type, suitable for general use and manufactured in accordance with the latest revision of SANS 1507 (Part 1 to 6).
The main supply cables from the Minisub room to the generator changeover and from the changeover to the laboratory DB shall be multi-core copper PVC\SWA\PVC insulated cables, with bare copper earthing, as per the drawings and as specified. The earthing must comply with SANS 10292 for low voltage distribution systems. The design and installation of an earth electrode system must comply with SANS 10199 and the earth electrode and couplers must conform to SANS 1063, should the existing earth system be inadequate.
12.1 Termination of Low Voltage Cables
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All accessories that are used shall be suitable for operation at 400/231 volts 50 Hz and compression and mechanical connectors must comply with SANS 61238-1. All cable ends shall be terminated with glands which comply with SANS 1213, complete with shrouds ensuring a watertight connection between the sheath, gland and equipment.
Gland lock nuts shall be of brass or stainless steel.
The shanks of all LV cable lugs shall be shrouded with colour coded heat shrink sleeves.
Exposed armouring shall be covered with bitumen-base paint.
Cable ends shall be supplied with the necessary earth connection. A wiring channel or other approved means of support shall be provided to remove mechanical stress from the cable glands.
The individual cable cores shall be connected to busbars, which comply with SANS 1195 or to the connecting terminals by means of crimped cable lugs of the correct size. The correct size of crimping die shall be used in the crimping apparatus for the connection of conductors to the cable lugs.
Only lugs of an approved type shall be used and hydraulic crimping tools shall be used in crimping. No hand crimping tools will be allowed.
The cable tails shall be arranged in such a fashion that a clip-on ammeter can readily be placed around any core.
13.0 CABLE TRAYS, LADDERS AND WIRE MESH TRAYS
The Sub-Contractor shall supply and install all cable trays or ladders required for electrical cables as well as all wire mesh trays required for data/telephone cables. The Sub-Contractor shall also supply and install all the necessary supports, clamps, hangers, fixing materials, bends, angles, junctions, reducers, T-pieces, etc. All cable trunking and ducting systems for electrical installations must comply with SANS 61084-1.
Tray type All cable trays shall be not less than medium-duty type perforated galvanized cable trays or return flange type. Cable ladders Cable ladders shall consist of galvanized metal with 50mm high side rail 2mm minimum thickness. Cross piece sections shall be spaced at maximum intervals of 250mm.
Where cables of 10mm2 or smaller are installed on cable ladders, the spacing of the cross pieces shall be 125mm. Cables shall be clamped in position by means of purpose made clamps that fit into the cross pieces.
Wire mesh trays Wire mesh trays shall be a minimum of medium duty hot-dipped galvanized type. Supports Trays and ladders shall be supported at maximum intervals of 1000mm. In addition trays and ladders shall be supported at each bend, off-set and T-junction.
Joints Joints shall be smooth without projections or rough edges that may damage the cables. The Sub-contractor will be required to cover joints with silicon or other hardening rubberized or plastic compounds if in the opinion of the Engineer joints may damage cables. Joints shall as far as possible be arranged to fall on
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supports. Where joints do not co-coincide with supports, joints shall be made by means of wrap- around splices of the same thickness as the tray and at least 450mm long. The two cable tray ends shall butt tightly at the centre of the splice and the splice shall be bolted to each cable tray by means of at least 8 round head bolts, nuts and washers. Splices shall have the same finish as the rest of the tray. Fixing Trays shall be securely bolted to supports to avoid cables being damaged during installation.
Fixing to the structure The supports for cable trays and ladders shall in all cases be securely fixed to the structure by means of heavy duty, expansion type anchor bolts. It is the responsibility of the Sub-contractor to ensure that adequate fixing is provided since cable trays and ladders that work loose shall be rectified at his expense. Accessories Horizontal and vertical bends, T-junctions and cross connections shall be supplied by the Sub-contractor. The dimensions of these connections shall correspond to the dimensions of the linear sections to which they are connected. The inside dimensions of bends shall be large enough to ensure that the allowable bending radii of the cables are not exceeded. Sharp angles shall have a 450 cornice. All accessories shall be galvanized.
Installation of cables Electrical cables shall be installed adjacent and parallel to each other on ladders or trays. Horizontal trays and ladders shall in general be installed at high level (on trusses), but in some instances where they are installed below slabs, ceilings, etc. they shall have sufficient clearance to facilitate access during installation.
Data/telephone cables shall be supplied and installed by others.
Earthing Metal trays and ladders shall be bonded to the earth bar of the switchboard to which the cables are connected. Additional bare copper stranded conductors or copper tape shall be bolted to the tray or ladder where the electrical continuity cannot be guaranteed.
Painting No painting of trays or ladders shall be required.
14.0 DISTRIBUTION BOARDS 14.1 Supply of Distribution Boards
The Electrical Sub-Contractor shall be responsible to supply and install Main DB (DB-LAB & DB-LAB/UPS) and SSO control panel as indicated on the layout drawings.
14.2 General
The switchboards shall comply in all respects to the provisions of SANS 10142 (as revised). Factory built distribution boards with a fault current rating up to and including 10kA must conform to SANS 1765 and factory built distribution boards with a fault current rating above 10kA must comply with SANS 1473-1. The switchboards shall be of ample size to accommodate all the specified switchgear with allowance of at least 40% additional space for future switchgear.
The Sub-contractor shall install the main DB and the control panel in the locations indicated on the drawings and shall arrange timeously for the installation of cable sleeves, openings in the structure and flush draw trays behind the D.B’s. where applicable. In general wall mounted switchboards shall be mounted 1500 mm above finished floor level - measured to the centre of the switchboard. The upper ends of switch-boards may not be higher than 2.3 meters above finished floor level, final positions to be approved by engineer on site.
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14.3 Construction of flush mounted switchboards
Bonding trays Bonding trays for flush mounted switchboards shall be of rigidly constructed 1.6 mm thick galvanized steel, braced and re-enforced. Formed gussets shall be provided at the corners. All the tray joints shall be properly welded. A brass or cadmium plated steel earth connecting stud and nut shall be provided. No flush mounted switchboards shall be installed in walls less than 230 mm in thickness.
Architrave frame The architrave frame shall be of 1.6 mm thick sheet steel with beveled edges. The architrave frame shall accommodate the chassis, panels and doors. The architrave shall overlap the bonding tray by at least 25 mm on each side. The architrave frame shall be fixed to the tray in such a fashion to allow for depth adjustment and irregularities of the wall.
Chassis The chassis for mounting of switchgear shall be of rigid construction and shall be fixed securely to the architrave frame or bonding tray by means of bolts screwed into tapped holes or bolts and nuts. Self-tapping screws are not acceptable. The chassis position shall be adjustable in the horizontal plane.
Panel A stiffened panel manufactured of 2.0 mm thick sheet steel shall be installed in the architrave frame for flush mounting of switchgear. The panels shall have machine punched slots for housing the specified and future switchgear, instruments, fuse holders, isolating switches, indicator lamps, etc.
Blanking plates shall be provided in positions where future switchgear will be installed. The distance between the inside of the closed doors and the panel shall be not less than 40 mm. No equipment may be mounted on the panel.
Fixing of panels The panel for each switchboard shall be secured to the architrave frame by means of 6 mm chromium plated studs. Alternatively, the panel may be secured to the architrave frame by means of two pins at the bottom and a latch or lock at the top of the panel. Self tapping screws will not be allowed. Where it is required that equipment be mounted on the panel, the panel shall be securely hinged to the switchboard frame.
Doors Where specified switchboards shall be equipped with doors. The doors shall be of a smooth flat finish suitably braced to ensure stiffness and when in the closed position, shall be flush with the architrave frame. The doors shall be of 1.6 mm sheet steel. The door width shall not exceed 600 mm. Doors exceeding 450 mm in width or height, shall on all four sides be bent inwards to ensure stiffness. The corners shall be welded and smoothed.
Door handles and catches All switchboard doors shall be equipped with lockable handles and catches. Where lockable doors are required and in all cases where the switchboard doors are higher or wider than 450 mm, handles consisting of a pushbutton-and-handle combination with spring loaded latch or rotary handle-and-catch combination shall be installed.
Switchboard doors smaller than 450 mm in height and width may be equipped with spring loaded flush mounted ring type latches. Square key operated catches are not acceptable.
14.4 Construction of surface mounted switchboards
Switchboard tray Surface mounted switchboards shall be equipped with a 1.6 mm sheet steel re- enforced tray. Securing lugs shall be provided to fix the tray to walls or any other structure. A solid brass or cadmium plated
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steel connection stud and nut shall be provided.
Construction All joints shall be securely welded. The tray shall be square and neatly finished without protrusions. The front tray sides shall be rounded with an edge of at least 20mm to accommodate flush doors. The requirements for chassis, panels and doors shall be as specified for flush mounted switchboards. The doors shall be hinged and shall fit flush in the frame in the closed position.
14.5 Mounting of equipment
Access All equipment, busbars and wiring shall be completely accessible when the front panels are removed.
Mounting of chassis The chassis of flush mounted and surface mounted boards shall be mounted on the tray, leaving sufficient space for wiring between rows of equipment and on the sides. This space shall also be adequate to pass the supply cable behind the chassis to connect to the main switch without making use of sharp bends.
Mounting of circuit breakers All moulded case circuit breakers shall be flush mounted with the toggles only protruding. Miniature circuit breakers may be installed in clip-in trays mounted on the frame. All other circuit breakers shall be bolted to the frame. Special provision shall be made for large main switches when designing the framework. Circuit breakers shall be installed so that the toggles are in the up position when "ON" and down when "OFF".
Instrumentation All metering instruments shall be mounted flush in the front panel unless otherwise specified. In certain instances it may be required that instruments be mounted flush in the door. In these instances the back of meters shall be covered by removable covers of isolating material fixed to the door to protect the terminals of instruments and to prevent accidental contact.
Fuses for instrumentation shall be mounted in an easily accessible position and marked clearly. Equipment mounted normally in an easily accessible position and marked clearly. Equipment mounted normally on the surface, e.g. time switches and relays, shall be mounted behind the front panel. In these cases hinged access panels shall be provided in the front panel.
Control equipment All equipment performing control functions, e.g. control relays, not requiring adjustments, shall be mounted behind the front panel. Bolts and nuts Cadmium-plated steel bolts only may be employed at connecting points. All bolts shall be provided with spring washers. Hexagonal nuts shall be used. The largest possible size of bolts that will fit into holes in lugs and fixing holes of equipment, shall be used in every instance. Bolts shall be of sufficient length so that not more than two threads protrude beyond the nut.
14.6 Busbars All busbars must comply with SANS 1195 and tested according to SANS 60439-1.
Mounting of busbars All busbars shall be installed horizontally or vertically with the longer side of the section in the vertical plane. Busbars must be supported on resin insulators. It is of prime importance that mechanical stressing under short circuit conditions must be considered when busbar supports are designed.
All busbars other than main busbars shall be mounted on suitable insulators or directly on circuit breaker terminals. Busbars shall be mounted at least 150 mm away from the nearest equipment. Special attention should be given to spacing between fuse switches and busbars.
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Covering The main busbars shall be covered with coloured heat-shrinkable PVC. The colour shall correspond to the colour of the supply phase. Busbars may alternatively be covered with two coats of coloured insulation paint if approved by the Engineer.
Connections All conductor ends shall be fitted with crimped lugs which are bolted to the busbar.
Neutral busbars Neutral conductors for circuits protected by a single pole circuit breaker of fuse switch shall be connected to a neutral busbar mounted in a suitable position. The neutral busbar shall have a cross-section of at least 6 x 25 mm and shall be long enough for the lugs of all the neutral conductors to be bolted separately to the busbar without overlapping the lugs.
Earth busbar Each switchboard serving socket outlets identified as dedicated outlets on the drawings shall be provided with separate earth bars which shall be referred to as a Building Earth and a Clean Earth respectively. Earth busbars shall be installed in convenient positions along the entire length of the switchboard. Building Earth busbars shall be bolted directly to the framework but Clean Earth busbars shall be mounted on resin insulators. Earth busbars shall have a minimum cross-section 6 x 20 mm and shall be installed in a suitable and easily accessible position over the full width of the board. 6 mm Diam. holes shall be provided in the busbar at 25 mm centres. All earth conductors shall be connected individually to the earth busbars. The holes provided shall be drilled on site to accommodate the bolts and nuts. Spare bolts and nuts need not be supplied.
All non-current carrying metal parts of the board, e.g. framework, panels, transformer cores, metal covers, etc.shall be bonded to the Building Earth busbar.
14.7 Circuit breakers
Circuit breakers, contactors and earth leakage units supplied and installed by the Contractor shall be CBi, MERLIN GERIN or ABB rated according to the fault level as indicated on the single line schematics. Where cascading of circuit breakers takes place, the system must conform to SANS 60947-2 or IEC 60947-2. Cascading and or co-ordination shall be to the board manufacturers specifications.
14.8 Wiring
Current ratings The current rating of conductors for the internal wiring shall be sufficient to carry the maximum continuous current that can occur in the circuit. This value shall be determined from the circuit breaker or fuse protection of the circuit.
Internal wiring Standard 600V grade PVC insulated stranded annealed copper conductors to SANS 1507 shall be employed for the internal wiring of switchboards, except where heat resisting cables to SANS 529 are required.
All wiring shall be arranged in horizontal and vertical rows and shall be bunched and strapped using "Hellerman" or similar strapping.
Under no circumstances may PVC adhesive tape be used for the bunching of conductors of for the colour identification of conductors.
Bunched conductors shall be neatly formed to present a uniform appearance without twisting or
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crossing the conductors. Conductors leaving harnesses shall be so arranged that they are adjacent to the chassis. These conductors shall first be led in the same direction as the conductors in the harness and shall then be bent over the top of the harness and progress to its final destination.
Conductors to hinged panels and doors shall be secured on both the door and the frame and shall be looped between the two points. The loop shall be arranged to produce a twisting motion when the door is opened or closed. A flexible protection sleeve shall be installed over the conductors.
All wiring between different panels within the same switchboard shall be separately bunched.
Grommets shall be installed in each hole in the metalwork through which conductors pass.
All wiring shall be installed away from terminals, clamps or other current carrying parts. Wiring shall also be kept away from exposed metal edges or shall be protected where they cross metal edges.
Conductors may be joined at equipment terminals or numbered terminal strips only. Ferruled and taped or other connections are not acceptable.
Where conductors change direction, smooth bends shall be formed with a radius of at least 5 times the outside diameter of the conductor or harness.
Where neutral connections are looped between the terminals of instruments, it is essential that the two conductor ends be inserted into a common lug and are crimped or soldered together in order that the neutral connection is not broken when the conductors are removed from one of the instruments.
Wiring should be confined to the front portions of switchboards as far as possible for ease of access. This requirement is important for wiring between circuit breakers with a rating of less than 30A and the associated main circuit breaker as well as the wiring from circuit breakers to lighting and socket outlet circuits.
Load End Connections The supply end connections to equipment shall as a rule be at the top and the load end connections at the bottom. Where the load and supply ends of the mains circuit breaker of a switchboard are not indicated the load may be connected to the top end only if the wording "LINE" and "LOAD" is correctly indicated on the circuit breaker.
Wiring to circuit breakers Loop connections may only be installed for a maximum of two outgoing circuits. Where there are more than two outgoing circuit busbars shall be used and equipment connected individually to busbars. Where MCB's are mounted in a continuous row and supplied by busbars connected to each MCB, each busbar shall be supplied by a separate conductor. This conductor shall be connected to the busbar by means of a separate lug and not via an MCB terminal.
Conductor terminations Connections to circuit breakers, isolators or contactors shall be installed by one of the following methods:
a) A ferrule of the correct size,
b) soldering the end of the conductor, or
c) winding a conductor strand around the end to totally cover the end.
All conductors terminating on meters, fuse holders and other equipment with screwed-on terminals shall be fitted with lugs. The lugs shall be soldered or crimped to the end of the conductor. Sufficient insulation shall only be stripped for the end to fit into the terminal. Strands may not be cut from the end
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of the conductor.
Identification The colour of the conductors for all 230V circuits shall correspond to the colour of the supply phase for that circuit. Neutral conductors shall be black. All other conductors in the board, supplying control circuits, etc. shall be coded in colours other than those specified above. A colour code shall be devised for each board and the colour code shall be shown on the wiring diagrams. All conductors that terminate at terminal strips and all conductors used for the internal wiring of the switchboard, shall further be identified at both ends by means of double cable marking ferrules. PVC or other tape is not acceptable. The numbers on the markers shall also be shown on the wiring diagrams.
14.9 Paint finish
Finish Required Metal components of the framework, panels and chassis shall be finished with a high quality paint applied according to the best available method. Baked enamel, electro-statically applied powder coating or similar proven methods may be used. Care shall be taken to ensure that all edges and corners are properly covered.
Colour The colour shall be as requested by the Engineer.
Before the installation is handed over the Contractor shall ensure that all painted surfaces are clean and undamaged.
Labelling Care shall be taken to ensure that all equipment is fully labelled and that accurate descriptions appear in both official languages. All SSO’s on UPS should be clearly labeled on control panel and each individual outlet.
Material Engraved plastic or ivory strips shall be used throughout. The strips shall bear white lettering on a black ground.
Equipment identified All equipment on switchboards shall be identified with the necessary labels. The circuit numbers shall appear at all grouped single pole circuit breakers. The abovementioned circuits shall be identified on a legend card, which shall be installed on the inside of the switchboard door, or in any other position where it can conveniently be observed. All fuses including instrument fuses shall have labels stating function, fuse rating and duty or type where applicable. All other equipment shall be identified separately and their functions shall be clearly indicated.
Where cascading of circuit breakers occur in a distribution board, a suitable label of notification must be provided.
Fixing of labels Engraved strips shall be secured by means of brass nuts and bolts or slotted label holders. Self tapping screws will not be allowed. Labels shall not be glued to the switchboard. Sufficient fixing bolts shall be provided to prevent labels from warping.
Tests The Engineer shall be notified when the mechanical construction of the switchboard i.e. frame, panels and baseframe, is completed in order that he or his representative may inspect it at the factory.
Function tests of all equipment, control and interlocking circuits shall be conducted to the satisfaction of the Engineer. The proper functioning of all protection relays and ammeters shall be proved by means of current injection on the primary side of the relevant current transformers.
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Testing equipment and facilities including instruments, dummy loads and additional switchgear and cables, at the factory or on site, shall be provided by the Contractor at no extra cost. The Engineer shall be notified in writing two weeks in advance of any tests to be conducted, to allow him or his representative to be present at such tests. A complete report on the tests shall be handed to the Engineer. The Contractor shall allow in his tender for all costs of travel and accommodation out of inspection by the Engineer should the boards not be manufactured in Cape Town.
14.10 Drawings
Drawings for approval A set of two prints drawings for the Distribution Boards shall be submitted to the Engineer for approval before alterations will be made. The following information shall be present:
A complete wiring diagram of the equipment on the boards.
A complete layout of the arrangement of the switchboards indicating all equipment dimensions and the construction of the boards. The positions and method of fixing of busbars shall be shown.
All labelling information in both the official languages on a separate sheet.
The make, catalogue number and capacity of all equipment such as isolators, circuit breakers, fuses, contactors, etc.
The approval of drawings shall not relieve the Sub-contractor of his responsibility to the Owner to supply the switchboards according to the requirements of this Specification.
Final Drawings A complete set of three "as-built" transparent drawings of all switchboards shall be submitted to the Engineer immediately after completion of the installation.
Manuals Two sets of manuals for all switchboards shall be forwarded to the Engineer at no extra cost. These manuals shall include the following information:
a) complete information on the operation of the equipment,
b) complete information for maintenance of the equipment,
c) brochures and ordering information, and
d) a complete material list indicating quantities and relevant catalogue numbers.
Completion The Sub-contract shall be regarded as incomplete unless all tests have been conducted successfully and all drawings and manuals have been handed to the Engineer.
15.0 WIRING CHANNEL INSTALLATION
Wiring channel shall be installed as indicated on the drawings. All metal wiring channels and accessories shall be of the O-line systems manufactured type or similar and shall conform to SANS 61084-1. Channels shall be installed complete with clip-on covers. Adjoining lengths shall be correctly aligned and securely joined by means of connection pieces that are pop-riveted to both abutting sections. All adjoining sections shall be of identical rectangular section and shall butt tightly. Covers shall fit tightly across the joint.
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Wiring channels shall be installed open end up, but where it is installed on its side or in vertical runs all conductors shall be retained by means of metal clips or metal spacer bars at not less than 1m centres. All channels shall be vermin proof once installed. Holes shall be covered by means of screwed metal plugs or by means of metal strips that are pop-riveted to the channel. Electrical and mechanical continuity shall be maintained throughout the wiring channel installation. A tinned copper-bonding strip shall be installed across each joint and secured to both adjoining lengths by means of brass bolts, nuts and washers. The channel shall be bonded to the earth bar of the associated switchboard. All bends shall be of easy sweep design with 450 cornices. Burrs and sharp edges shall be removed and the inside edges of all joints shall be lined with silicon or other suitable rubberised compound to prevent conductor insulation laceration.
Wiring channel shall be large enough to ensure that the combined total cross-sectional area (including insulation) of all conductors does not exceed 40% of the cross-sectional area of the channel.
The Sub-contractor shall supply and install all hangers, supports or fixings. Wiring channels up to 127 x 75mm shall be supported at maximum intervals of 1500mm and where suspended from the roof structure this shall be done using OL 3300 and threaded galvanized rods or appropriate hangers. Channel runs shall be in the top 150mm space of the ceiling void and be carefully planned to avoid clashes with other services and to ensure that all covers can be removed after completion of the entire installation.
All conduit connections shall be terminated by means of a bush. All holes through which conductors pass shall be equipped with grommets.
16.0 POWER SKIRTING
Power skirting shall be supplied and installed in the positions indicated on the relevant drawings. The power skirting shall be of the Cabstrut Jupoiter PVC type or similarly approved by the Engineer. The Sub-contractor shall be responsible for the complete supply and installation of all power skirting and accessories. All associated connections, 900 bends, tees and end caps shall be purpose manufactured units and all sections of ducts and lids shall be cut square and have their edges "faced" to the approval of the Engineer.
Socket outlets, telephone outlets and infill plates shall be purpose made accessories stamped to receive respective outlets, all as detailed on the drawings.
Power skirting will only be installed after all wet trades have been completed and the Sub-contractor shall be responsible for protecting the power skirting to the approval of the Engineer. The Sub-contractor shall be responsible for the complete supply and installation of all power skirting including all accessories, associated connections, bends, tees and end caps to the approval of the Engineer.
Conduit links indicated on the drawings shall rise out of the floor slab directly behind the power skirting. Linking conduits shall not be closer than 150mm throughout their length.
Where applicable all cutouts for service connections shall be grommeted with "U" section neoprene trim secured to the Engineer's approval.
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17.0 CONDUIT INSTALLATION 17.1 General
Conduit may be installed as follows: a) In open roof spaces,(Galvanized or Bosal) b) cast in concrete, (Galvanized or Bosal) c) surface mounted against walls, concrete slabs, etc.(Galvanized or Bosal) and d) in wall chases. (Galvanized or Bosal)
Metal conduits and fittings must conform to SANS 1065-1 and SANS 1065-2. Unplasticised polyvinyl chloride rigid conduit and fittings must comply with SANS 950. Conduits are to be installed in concrete shall be done while the building work is still in progress and according to the Main Contractors program. No conduits or sleeves will be allowed in the floor of the process and racking area.
Surface fixed conduits shall be installed on all columns and walls in the process and racking area.
17.2 Other Services
Conduits shall be installed at least 150mm away from pipes which are intended for gas, steam, hot water or any other material which may effect the conduit. Where doubtful situations of this nature occur or where there are installation incompatibilities the matter shall be reported to the Engineer without delay.
17.3 Debris
Care shall be taken to prevent any debris or moisture from entering the conduit during and after installation of the conduits. All conduit ends shall be sealed.
17.4 Defects
Each length of conduit shall be inspected for defects and all burrs shall be removed. All conduits that are split, dented or otherwise damaged or any conduits with sharp internal edges shall be removed from site. The Sub-contractor shall ensure that conduits are not blocked.
17.5 Continuity
Electrical continuity shall be maintained throughout the conduit installation by provision of bare copper or PVC insulated earth wires which shall be drawn in simultaneously with circuit wiring.
17.6 Inspection Type Accessories
All outlet boxes and draw boxes shall be of the inspection type and shall conform to SANS 1085. 17.7 Positions of Outlets
All accessories such as socket outlets, switches, lights, etc. shall be accurately positioned. It is the responsibility of the Sub-contractor to ensure that all accessories are installed level and square at the correct height from the floor, ceiling or roof level as specified. It shall be the responsibility of the Sub-contractor to determine the correct final floor, ceiling and roof levels. Draw boxes shall not be installed in positions where they will be inaccessible after completion of the installation.
Draw boxes shall be installed in inconspicuous positions to the approval of the Engineer. All installed draw boxes shall be pointed out to the Engineer. The positions of all draw boxes shall be indicated on the “as built” drawings.
17.8 Draw Wires
Galvanized steel draw wires shall be installed in all unwired conduits eg. conduits for future extensions, data/telephone conduits, security installations and other services.
17.9 Bends
A maximum of two 900 bends or the equivalent displacement will be allowed between outlets and/or draw boxes. Draw boxes shall be installed at maximum intervals of 9m in straight conduit runs. All bends shall be made without reducing the diameter of the conduit.
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17.10 Wall Sockets
Where more than one socket outlet is connected to the same circuit, the conduit shall be looped from one outlet box to the following on the same circuit. Where a metal channel is used, the conduit may be installed from the channel directly to the outlet box on condition that the conductors can be looped from one outlet to the next without making any joints in the wires.
17.11 Light Fittings
Conduit ends may not be used to support light fittings. In all cases light fittings must be supported by the structure against or in which they are installed.
17.12 Withdrawal of Conductors
To ensure that all electrical conductors shall be easily removable from conduits, the Engineer reserves the right to have the conductors of any circuit removed at his discretion and replaced at the cost of the Sub-contractor. If the conductors are damaged during removal, the damaged conductors shall be replaced and the cost of the replacement shall be borne by the Sub-contractor.
17.13 Flush Mounted Outlet Boxes
The edges of flush mounted outlet boxes shall not be deeper than 10mm from the final surface. Where this is not the case, an extension box which ends flush with the surface, shall be screwed to the outlet box. This method shall be used in partitions and cladded surfaces.
17.14 Roof or Ceiling Spaces
Sequence of Work in Roof or Ceiling Spaces (where applicable) Conduit and wiring in spaces above ceilings other than concrete shall be installed before the ceilings and walls are painted and before removable ceiling tiles are installed. In roof spaces where access is limited after installation of the ceiling, conduits and wiring shall be installed prior to installation of such ceilings. It is the responsibility of the Sub-contractor to ensure close liaison with the other Sub-contractors is done in connection with the above-mentioned work.
Fixing All conduits in roof or ceiling spaces shall be installed parallel and at right angles to the roof members and shall be fixed to the structure at intervals not exceeding 1 metre. Approved saddles shall be used throughout. Clout nails, clamps or wood screws shall be used to secure the saddles to wooden roof members. Suitable saddles shall be used to secure conduits against concrete slabs. Written permission shall be obtained to secure conduits to steel beams in which case saddles shall be fixed by means of bolts, nuts and lock washers or purpose made saddles shall be used.
Draw Boxes Draw boxes with PVC cover plates shall be installed where required. Draw boxes shall as far as possible be installed near walkways. Socket and switch boxes will not be accepted as draw boxes in open roof spaces. Conduit Ends All conduit boxes for lighting outlets in ceilings shall be securely supported.
17.15 Installation in Concrete
In order not to delay building operations, the Sub-contractor shall ensure that all conduits and accessories that are to be cast in concrete are placed in position within good time. The Sub-contractor or his representative shall be in attendance when the concrete is cast.
Draw Boxes
Draw boxes, expansion joints and round ceiling boxes shall be installed where required and shall be neatly finished to match the finished slab and wall surfaces. In columns where flush mounted draw boxes are installed, the conduits shall be offset from the surface of the column immediately after leaving the draw box.
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Elbows Elbows for conduits of 32mm dia. and smaller and sharp bends will not be allowed in concrete slabs.
Cover Plates Draw boxes and/or inspection boxes shall where possible, be grouped together under a common approved cover plate. The cover plate shall be secured by means of screws.
Neutral Axis All conduits shall be installed as close as possible to the neutral axis of concrete beams, slabs and columns. The conduits shall be rigidly secured to the reinforcing to prevent movement towards the surface of the concrete.
Fixing to the Shuttering All conduits, draw boxes, etc. shall be securely fixed to the shuttering to prevent displacement when concrete is cast. Draw boxes and outlet boxes shall preferably be secured by means of a bolt and nut installed from the back of the box through the shuttering. Fixing lugs may also be used to screw the boxes to the shuttering. Wire will not be accepted for securing boxes to the shuttering where off-shutter finishes are required. All draw boxes and outlet boxes shall be plugged with wet paper before they are secured to the shuttering. Expansion Joints As far as possible, conduits shall not be installed across expansion joints. Where this is unavoidable and expansion joint shall be provided.
Screeds The installation of conduits in floor screeds shall not be allowed unless consent from the principal agent is obtained in writing. Where conduits are installed in screeds, the top of the conduit shall be at least 20mm below the surface of the screed. Where the screed is laid directly on the ground, galvanised conduits shall be used. This ruling will always be applicable to the lowest floor of a building. A minimum distance of twice the outside diameter of the conduit shall be left free between adjoining conduits. Conduits shall be secured to the concrete slab at intervals not exceeding 2.0 metres. The Sub- Sub-contractor shall ensure that conduits are not visible above the screed where the conduits leave the screed.
Structural Steel Supports, brackets, hangers, etc. may only be welded to structural steel members where prior permission of the Engineer has been obtained. “CADDY” or similar fasteners may be used to fix equipment to structural steel members.
17.16 Surface Conduits
Only surface conduits shall be allowed in the process and racking area. 17.17 Flexible Conduit
In installations where the equipment has to be moved frequently to enable adjustments during normal operation, for the connection of motors or any other vibrating equipment, for the connection to thermostats and sensors on equipment, for stove connections and where otherwise required by the Engineer, flexible conduit shall be used for the final connection to the equipment.
The lengths of flexible conduit shall be as short as possible to comply with the requirements of the particular connection but shall not exceed 600mm, except when specified or approved by the Engineer.
Flexible conduit shall preferably be connected to the remainder of the installation by means of a draw box. The flexible conduit may be connected directly to the end of the conduit if an existing draw box is available within 2000mm of the junction and if the flexible conduit can easily be rewired.
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Flexible conduit shall consist of metal-reinforced plastic conduit or PVC covered metal conduit with an internal diameter of at least 15mm, unless approved to the contrary. Connectors for coupling to the flexible conduit shall be of the gland or screw-in type, manufactured of either brass of cadmium or zinc plated mild steel. Where the possibility exists that the conduit can come into contact with moisture, suitable covering and/or packing shall be installed to isolate the conduit from the moisture.
Flexible conduit connections shall be provided with an internal or external earth wire connection as required by the local Supply Authority, with preference given to internal earth wires where no specific local regulations apply.
17.17 Expansion Joints
Where conduits cross expansion joints in the structure, approved type draw boxes, which provide a flexible connection in the conduit installation, shall be installed.
The draw box shall be installed adjacent to the expansion joint of the structure and a conduit sleeve, one size larger than that specified for the circuit, shall be provided on the side of the draw box nearest the joint. The one end of the sleeve shall terminate at the edge of the joint and the other shall be secured to the draw box by means of locknuts.
The circuit conduit passing through the sleeve shall be terminated 40mm inside the draw box and the conduit end fitted with a bush. The gap between the sleeve and the conduit at the joint shall be sealed to prevent the ingress of wet cement. The other end of the circuit conduit shall be secured to the draw box by means of locknuts and a bush. Draw boxes at the expansion joint shall be provided with a suitable cover plate fixed to the box by means of screws. The cover plates shall be installed before the ceilings are painted by others.
Where a number of conduits are installed in parallel they shall cross the expansion joint of the structure via a single draw box. A number of draw boxes adjacent to each other will not be allowed.
18.0 WIRING
Except in cases where cables are specified, all wiring shall be PVC insulated, single core stranded copper conductors and bare stranded or green/yellow PVC insulated copper conductors for earth continuity in compliance with SANS 1507.
All conductors shall be installed in conduits, trunking or power skirting and shall under no circumstances be installed without mechanical protection.
Wiring in partitioning systems may be done using suitably rated ‘Twin & earth’ cable. Wiring shall only be carried out after the conduit or trunking installation and plasterwork is completed, but before painting has commenced. No conductors shall be installed before the conduits have been cleaned of all debris and moisture. Conductors that are connected to different switchboards shall not be installed in the same conduit or trunking.
The wiring of one circuit only will be allowed in 20mm dia. conduit with the exception of the wiring between switchboards and fabricated sheet metal boxes close to switchboards in which case more than one circuit will be allowed.
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All wiring shall be carried out according to the loop-in system. If a conductor joint is found necessary in an isolated case, jointing will only be accepted in trunking and not in conduits. Conductor jointing shall be executed by approved ferruling, properly covered with heat shrink sleeving.
The number of conductors that may be drawn through a conduit shall comply with the requirements of the SANS 10142. The total cross-sectional area of the conductors (including insulation) in trunking or power skirting shall not exceed 40% of the cross-sectional area thereof. In cases where the conductors of more than one circuit are installed in trunking or power skirting, the conductors of each separate circuit (earth conductor inclusive) shall be taped at intervals of one meter with PVC insulation tape. The conductors of different circuits shall however remain separate in order that any given circuit can be withdrawn. Conductors entering switchboards or control boards shall be grouped and bound by means of plastic binding.
When conductors are drawn through conduit, care shall be taken that they are not kinked or twisted. Care shall also be taken that the conductors do not come into contact with materials or surfaces that may damage or otherwise adversely affect the durability of the conductor.
With the exception of three phase outlets, circuits of different phases shall not be present in lighting, switch or socket outlet boxes.
Conductors installed in vertical conduit or trunking shall be secured at intervals not exceeding 15m to support the mass of the conductors. Clamps shall be provided in suitable draw boxes for this purpose.
The insulation of conductors shall only be removed over the portion of the conductors that enter the terminals of switches, plugs or other equipment. When more than one conductor enters a terminal, the strands shall be securely twisted together. When earth continuity conductors are looped between terminals or equipment, the looped conductor ends shall be twisted together and then soldered or ferruled to ensure that earth continuity is maintained when the conductors are removed from a terminal.
Cutting away of conductor strands will not be allowed. The colours of conductor insulation for wiring purposes shall comply with the wiring regulations. The colours of conductors for sub-circuits shall as far as possible correspond with the colour of the supply phase. The colours of conductors for wiring to two-way and intermediate switches shall differ from phase conductors. The light return shall also differ in colour from the phase supply and all colours to be constant throughout the installation. Single pole switches shall be connected to the phase conductor and not to the neutral conductor.
The following minimum conductor sizes shall be used:
a) Lighting circuits 2.5mm2 plus 1.5mm2 earth conductor b) DC light circuits 4mm2 plus 2.5mm2 earth conductor c) Plug circuits 2.5mm2 plus 2.5mm2 earth conductor d) Stove circuits 6mm2 plus 6mm2 earth conductor e) Motor circuits 4mm2 plus 2.5mm2 earth conductor When wiring is installed in partitioning, the vertical and/or horizontal supports of the walls may be utilized for fixing wiring on condition that PVC multi-core cables with metal stiffening is used as an alternative to wiring in conduit.
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19.0 SWITCHES AND SOCKET OUTLETS 19.1 Flush switches
All switches shall comply with SANS 163 as amended and shall bear the SANS mark. All switches and socket outlets shall be of the Clipsal S2000 range or equivalent. Switches shall be rocker or toggle action and shall be rated at minimum 16A. Light switches shall be of the modular type, which can be installed in standard outlet boxes.
Single or double gang switches shall be installed in such a fashion that the toggle or rocker action is vertical.
19.2 Surface mounted switches
Surface mounted switches shall consist of single or multi-gang switch units mounted in a common box. Rocker or toggle action shall be vertical. The box and cover shall be of heavy gauge approved metal with all corners and sides rounded. The cover shall fit neatly over the box and shall be fixed by means of at least two chromium plated counter-sunk screws. The switch toggle or rocker shall be shrouded where it protrudes through the cover. The switch units shall bear the SANS mark and shall comply with SANS 164 as amended and SANS 163 as amended where applicable and with the test requirements of SANS 109 as amended.
19.3 Installation of light switches
Mounting height All light switches shall be installed 1250mm above the finished floor level unless specified on the drawings. Mounting heights given shall be measured from the finished floor level to the centre of the switch.
Doors Unless otherwise specified switches adjacent to doors shall be installed on the side containing the lock. If the position of the lock is not shown on the drawings, the position shall be verified before the switch box is installed. Switch boxes in brick or concrete walls, shall be installed 150mm from the doorframe. Light switches installed in partitions or doorframes shall be of the type designed for that purpose.
Walls Where the wall is plastered, light switches must be installed flush with the plaster finish. Cover plates Bevelled cover plates which overlap the switchbox and which fit tightly against the wall finishes shall be installed in the case of flush mounted switch-boxes. Suitable spiral type steel wire spacers shall be used to fix the cover plate to deep-set flush switch-boxes. All fixing screws in cover plates and switch grids shall be supplied and securely fitted. The colour of cover plates shall be to the Architect's choice. Cover plates shall under no circumstances be cut unless specifically authorised in exceptional cases by the Engineer. Switch boxes and cover plates shall be installed parallel to the relevant horizontal and vertical building lines.
Partitions Light switches installed in partitions shall be of the type designed for this purpose to be accommodated in the partition design. Switches installed in the metal support do not require switch boxes. Switches may not be flush mounted in partition walls without switch boxes.
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Multiple switches Where specified, multi-gang switches shall be installed in a common box. Switches controlling different circuits shall be installed in separate switch boxes. Appearance The sides of adjacent switches, plugs, pushbuttons, etc. shall be parallel or perpendicular to each other and uniformly spaced. A common escutcheon plate shall be used for flush mounted outlets and accessories where the cover plates do not cover the cut-outlets in the finishes.
19.4 Socket outlets
The following different types of socket outlets will be supplied by the Sub-contractor and installed in the building as shown on the drawings (all socket outlets shall be of the Clipsal S2000 range or equivalent):
a) General purpose socket outlets - These shall be 16 Amp 3-pin switched type to SANS 164. They
shall either be mounted in power skirting, flush or surface mounted in 100 x 100 boxes or surface mounted as described below. They shall be of the modular type, suitable for installation in standard outlet boxes.
b) Dedicated socket outlets – These shall be 16A 3-pin switched type, with a half round earth pin.
These outlets shall be red. They shall be of the modular type, suitable for installation in standard outlet boxes.
c) Three-phase or single-phase socket outlets to comply with SANS 1239.
The earth conductors of all of these sockets will be Green/Yellow insulated PVC earth conductors wired back to the “Building Earth” bar on the nearest switchboard.
19.5 Flush socket outlets (SANS Type)
Flush socket outlets shall each consist of a switch and 3 pin plug receptacle with 2 shuttered poles and an earth socket suitable for mounting in a standard pressed steel box under a common cover plate. Sockets and switches shall be rated at 250V, 16A unless clearly specified to the contrary. Switches shall comply with SANS 163 and sockets shall comply with SANS 164.
19.6 Surface mounted socket outlets (SANS Type)
Surface mounted socket outlets shall consist of a switch and 3 pin plug receptacle with 2 shuttered poles and an earth socket contained in a pressed steel box suitable for surface mounting.
The box and cover plate shall be manufactured of 1.6mm steel with all corners rounded. The lid shall fit neatly over the box and shall be fixed by means of two counter-sunk screws. A knockout shall be provided on each side of the box for the termination of 20mm conduits.
The switch toggle shall be shrouded where it protrudes through the cover plate.
Sockets and switches shall be rated at 250V, 16A. The unit shall comply with SANS 163 and SANS 164 where applicable and shall be tested in accordance with SANS 109 as amended.
19.7 Installation of socket outlets
Mounting heights, unless otherwise specified, outlets shall be installed at the following heights above finished floor level:
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a) Flush mounted socket outlets in general 300mm b) Surface mounted socket outlets in general 1300mm c) Kitchens surface or flush mounted 1250mm d) Plantrooms, stores, parking garages and workshops - surface or flush mounted 1400mm e) Passages - surface or flush mounted 300mm f) Office areas - surface or flush mounted
(Excluding power skirting) 300mm
All mounting heights shall be measured from finished floor level to the bottom of the outlet box.
Cover plates Cover plates for flush socket outlets shall be manufactured from a non-ferrous metal with a thickness of not less than 1.2mm. The colour of cover plates shall be to the Architect's choice.
20.0 LIGHT FITTINGS 20.1 Supply of light fittings
All light fittings are as shown on drawings and as per the luminaire types and quantities as scheduled in the bill of quantities. The Sub-contractor shall allow in his tender for the supply, delivery, offloading on site, storing, handling, installing, cleaning and commissioning of all indoor and outdoor luminaries as indicated on the drawings. The Sub-contractor shall be held liable for any damage to luminaires from the date of receipt until date of handover to the Client.
20.2 Installation of light fittings
The various types of light fittings required in the execution of the contract will be shown on the drawings and are listed in the bill of quantities. Each high level fitting in the processing and racking area shall have a flexible cord of 2,5m attached to it and a 5 amp plug top attached to the other end. The P9000 trunking from which the fittings are suspended shall have an un-switched socket outlet, to comply with SANS 164-1, for each light fitting. In the case of emergency fittings, the socket outlet will be red in colour. Positions The mounting positions of light fittings shall be verified on site. All fittings shall be placed symmetrically with respect to ceiling panels, walls, columns or other architectural features of the space. The layout as shown in the drawings shall generally be adhered to but any discrepancies or clashes with structural or other features must be referred to the Engineer before commencing erection of the installation. Should the Sub-contractor neglect to refer such discrepancies to the Engineer, cost incurred as a result of subsequent alterations to suit the architectural features will be to the Sub-contractor's account.
Hangers and supports Where provision has not been made for the support of fittings, the Sub-contractor shall supply the necessary supports, hangers, conduit extensions, angle brackets or any fixing method approved by the Engineer. Ceilings In all cases where light fittings are installed in ceilings, the ceiling shall be capable of carrying the weight of the fittings. Ceilings shall either be of the open 'T' acoustic tile or plaster board type. When installing fluorescent fittings in ceilings, a gap shall not be visible between the fitting and the ceiling. Fittings shall be constructed for installation from below.
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Continuous rows of light fittings In cases where fluorescent fittings are installed in tandem, only one connection point need to be supplied per circuit. All fittings shall be coupled to one another by means of nipples or bushes and lock nuts to ensure that the wiring is not exposed and that earth continuity is maintained. Fittings on the same circuit may be wired through the channel formed by the fitting canopies. In this case silicon-rubber insulated conductors shall be used and internal connections shall be made at terminal blocks, Screw connectors are not acceptable. The wiring for any other circuits or outlets, even though these may be in the same row may not be installed through the fitting canopies. The Sub-contractor shall ensure that continuous rows are straight and parallel to the relevant building lines.
Recessed light fittings Where recessed light fittings are indicated the Sub-contractor shall maintain close liaison with the ceiling Sub-contractor. In the case of tiled ceilings, the fittings shall be installed while the metal supports are being installed and before the tiles are place in position. The Sub-contractor shall be responsible for the co-ordination of the cutting of ceiling tiles or plasterboard with the ceiling Sub-contractor. All mounting rings and other accessories shall fit closely into cut-outs to ensure a proper finish.
Vapourproof light fittings Waterproof and flameproof fittings shall be screwed directly to the conduit end. Draw boxes that may be required must be approved by the Engineer beforehand. Body should be smooth to avoid dust or particle collection, no clip for the diffuser should be allowed, diffuser to be connected to main body by 6x Allen-keys screws. Bulkhead fittings Surface mounted bulkhead fittings shall not be screwed directly to conduit ends. The conduit shall terminate in a round draw box at the back of the fitting. The PVC insulated conductors shall terminate in a porcelain terminal block in the draw box. Silicon-rubber insulated conductors shall be used from the terminal block to the fitting lampholder. Screw connectors will not be allowed. Switching of External light fittings All external lighting shall be photocell switched. The photocells shall be so positioned so as to minimise spurious switching from outside light sources. Furthermore the time delay shall be incorporated into the circuit to prevent spurious switching from short-lived light sources such as car lights.
The contacts of the photocell shall be rated at not less than 6A and shall be designed to close the lighting circuit at 25-35 lux and to break the circuit at 65-75 lux. The unit shall fail with its contacts in the closed position to facilitate identification of the faulty device.
21.0 AIRCONDITIONING OUTLETS
The Electrical Sub-contractor shall be responsible for the following:
a) Supply and installation of all wiring, wire ways and isolators for each of the A/C units. b) Circuit breakers on the various distribution boards to feed the A/C circuits. c) All external units shall be supplied via an armoured cable, ending in a waterproof isolator. All
isolators shall be installed within 1000mm of the A/C units. 22.0 FIXING OF MATERIALS
Responsibility It is the responsibility of the Sub-Contractor to position and securely fix conduits, trunking, cables and cable ladders, switchboards, fittings and all other equipment or accessories required for the installation. The Sub-Contractor shall provide and fix all supports, clamps, brackets, hangers and other fixing materials.
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Welding Supports, brackets, hangers, etc. may only be welded to steel structural members where prior permission has been obtained. Screws and bolts Where holes in equipment to be fixed already exist, bolts and fixing screws shall be used.
Wall plugs Where the fixing holes in brick or concrete walls are smaller than 10mm dia. and where the mass of the equipment is less than 15kg, wall plugs may be used to fix conduits, cables and other equipment. Aluminium, fibre or plastic plugs only may be used. Wooden plugs are not acceptable. Plugs installed in seams between bricks are not acceptable. A masonry drill of the correct size shall be used to drill holes for plugs. Round-headed brass screws shall be used throughout. Anchor bolts Where the fixing holes are 10mm and larger or where the mass of the equipment is 15kg or more, equipment shall be fixed by means of expanding anchor bolts.
23.0 CONNECTIONS 23.1 Connections to light fittings
Connectors Connections to the wiring of light fittings and other appliances where connectors are used, shall be effected by means of brass screw couplers shrouded in porcelain, neoprene or PVC or by means of approved spring steel locking connectors insulated in unbreakable material. Other types of connectors are not acceptable.
Knock-outs Where the wiring to light fittings and other appliances passes through knock-outs, brass bushes or rubber grommets shall be used to protect the insulation against laceration. Incandescent fittings Connections to fittings with incandescent lamps shall be installed in a box situated behind the fitting.
Fluorescent fittings Connections to fittings with fluorescent lamps other than those provided with flexible leads and plugs may be installed inside the metal body on condition that the frame and/or diffuser holder where applicable can be removed without disconnecting the conductors. Screwed lampholders The central terminal of Edison Screw (E.S.) lampholders shall be connected to the phase conductor (i.e. conductor with red insulation) and the screwed housing to the neutral conductor (i.e. conductor with black insulation).
23.2 Stove and kitchen appliances and connections
The connection to each stove or similar appliance unless specified to the contrary, shall consist of 6mm2 silicon insulated conductors and a 4mm2 bare copper earth wire in a 25mm conduit. A 60A double pole micro gap isolator shall be flush mounted in a wall outlet box behind or adjacent to the stove or appliance to be fed and must comply with SANS 60309-1 or IEC 60309-1. The height of the isolator to be at least 1250mm but not more than 1700mm above the finished floor level. The cover plate shall either fall entirely within the tiles surface or entirely within the plastered surface. The conduits shall terminate 450mm above the floor behind the stove or appliance with the end set out of
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the wall pointing downwards. The connection from the conduit end shall be by means of flexible conduit of sufficient length to enable the stove or appliance to be moved 600mm from its normal position for cleaning or maintenance purposes.
Crimped lugs shall be provided on all conductors or cable cores for connections to stoves or appliances. Soldered lugs may not be used.
Each stove or similar appliance shall be connected to a separate circuit and each shall have a separate earth conductor.
24.0 DATA /TELEPHONE , FIRE DETECTION & ACCESS CONTRIOL INSTALLATION
This specification covers only the supply and installation of outlet points, wire mesh trays, trunking and conduits for the data/telephone , fire detection and access control systems intended for the buildings. Others will carry out the supply and installation of equipment, cabling and terminations.
All conduits supplied and installed by the Contractor shall be provided with galvanised steel draw wires Conduit connections to power skirting shall be made by means of a draw box flush mounted immediately behind the duct or channel in which the electronic cables are to be installed. A hole shall be cut in the back of the duct or channel and edges of the hole shall be grommeted. The draw box or channel shall be accessible from the front when the power skirting cover is removed.
Outlets in walls, ceiling voids or partitioning shall consist of flush mounted 100 x 100 x 50mm draw boxes with blank cover plates or 60mm dia. round draw boxes with blank cover plates as specified and shown on drawings.
Where power skirting is shown the Sub-contractor need only install the skirting with covers since the data/telephone outlet sockets will be fixed directly to the cover. No other cables may be installed in the section intended for electronic cables and the separation between the sections shall be maintained throughout the installation. Data/telephone outlets on draw boxes and power skirting shall be supplied by others.
Outlets on Trunking Cabling and the installation of the data outlets or telephone sockets fixed the sides of wiring trunking shall be by others.
25.0 EARTHING
General The installation shall be earthed properly in accordance with the latest revision of SANS 10142 and separate earthing systems shall be provided for the Building Earth and the Clean Earth. Earthing to comply with SANS 10292 for low voltage distribution systems. The design and installation of an earth electrode system must comply with SANS 10199 and the earth electrode and couplers must conform to SANS 1063. All earth conductors for the Building Earth shall be bare stranded copper conductors except that stranded conductors with Green/Yellow PVC insulation shall be used in trunking or power skirting. Earth conductors for the Clean Earth system shall be stranded conductors with Green/Yellow insulation.
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A separate earth connection shall be supplied between the Building Earth busbar in each switchboard and the earth busbar in the Main LV Board. These connections shall consist of bare stranded copper. Similarly a separate earth connection will be supplied between the Clean Earth busbar in each switchboard and its earth spike or mat. The earth conductors of all circuits shall be connected to the appropriate earth busbar of the supply board. All single-phase socket outlet circuits shall be supplied with 2.5mm2 earth conductors. All fluorescent lighting circuits shall be supplied with 2.5mm2 earth conductors. All single phase and three phase outlets, electrical appliances, equipment, electrical motors, etc. shall be earthed as stipulated in SANS 10142. All outlets in the building identified on the drawings as dedicated socket outlets shall be provided with Green/Yellow insulated earth wires and earthed to the Clean Earth bar in the appropriate switchboard.
Connections Under no circumstances shall any connection points, bolts, screws, etc. for earthing be utilized for any other purpose. It will be the responsibility of the Contractor to supply earth terminals or clamps where not provided by others. All earth connections shall be tinplated and fixed with approved ferrules. The entire connection shall then be soldered.
Power skirting All power skirting to accommodate socket outlets shall be earthed with 2.5mm2 Green/Yellow PVC insulated earth conductor. This conductor shall be installed over the entire length of the power skirting and connected to the Building Earth busbar in the nearest switchboard. The conductor shall be bolted to the skirting on both sides. The conductor may not be used as an earth conductor for the plug circuits and shall be independent of any other conductor.
Wiring channel, cable trays and ladders The ends of all metal channels, cable trays and ladders containing cables or conductors under load shall be earthed to the Building Earth busbar in the nearest switchboard with copper strapping or 2.5mm2 stranded conductors. Adjoining sections shall be connected at joints with copper strapping or 2.5mm2 conductors. Flexible conduit An external earth conductor shall be installed together with all non-metal flexible conduits. The earth conductor shall be connected securely to the metal parts. Water pipes( Bonding) Metal cold water mains shall be connected with solid 12 x 1.6mm copper strapping to the earth busbar in the Main LV Board. All other hot and cold water pipes shall be connected with 12 x 0.8mm perforated or solid copper strapping (not conductors) to the nearest switchboard. The strapping shall be fixed to the pipe work with brass nuts and bolts and against walls with brass screws at 150mm centres. In all cases where metal water pipes are positioned within 1.6m of switchboards an earth connection consisting of copper strapping shall be installed between the pipe work and the board. In the vertical building ducts accommodating water pipes all the pipes shall be earthed to the nearest switchboard.
26.0 PHOTOELECRICAL SWITCHES FOR THE CONTROL OF EXTERNAL LIGHTS
General All photoelectric control units for lighting shall comply with SANS 1777. The switches will be used for the control of external lighting and shall be provided with switching contacts that can carry a minimum current of 5A. The current under no-load conditions shall not exceed 50mA. The units shall be suitable for use on a 230V approx. 6%, 50Hz, single-phase alternating current system.
Construction The units shall be weather-proof and resistant against vibration as it will be
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mounted outdoors for activation purposes. The design shall be of such a nature that the units shall be protected against damage from strong wind or hail. The unit shall have a hole in the base with a diameter of 20mm and shall be provided with electrically metrical thread which shall be compatible with a 20mm diameter electrical conduit. All components shall be treated against corrosion.
Operating conditions
The units shall be suitable for operation in dusty conditions at temperatures of –50 C to 550C.
Pre-determined lighting levels The units shall switch on when the lighting level has dropped to 15 lux approx. 20% and shall switch off when the lighting level reaches 40 lux approx. 20%. The unit shall have a time delay of 2 minutes in the ON position before switching off should a sudden rise in lighting level occur. The design of switch shall be of such a nature that it will always ensure a positive switching action.
27.0 Access control system General The door indicated on the design drawing should be controlled via a card reading access control system with magnetic lock door fittings complete with wiring and door closers. The existing system would be programmed to accommodate the new installation the following sequence. Both readers to be activated by same access card before push button release will allow person to exit. From any one of the two doors. All fittings to be SABS approved and to be approved by Engineer. Contractor to investigate existing system to ensure compatibility with new proposed system.
28.0 INSPECTION AND TESTING On completion of the entire installation or any particular section thereof, as may be decided by the Engineer, tests shall be carried out in full accordance with the current edition of SANS 10142-1, the “Code of Practice for the Wiring of Premises”, in the presence of the Engineer or his authorised Representative. The Contractor should note that where applicable at least the following tests must be carried out:
LV Installation 1. Continuity of bonding conductors 2. Resistance of earth continuity conductor 3. Continuity of ring circuits 4. Earth fault loop impedance at the main switch 5. Elevated voltage on supply neutral 6. Earth resistance test 7. Insulation resistance 8. Voltage, under no load and load conditions 9. Operation of earth leakage units 10. Phase rotation and polarity 11. Any further test to meet the local Supply Authority Agreements or as deemed necessary by the
Engineer Note:
1. All instrumentation necessary for testing shall be provided by the Sub-contractor.
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2. The results of the above tests must be clearly recorded, signed and handed to the Engineer. 3. Once the Engineer has inspected the complete installation and satisfied himself that all testing has
been completed and the Sub-Contract is complete in all respects, may the Engineer be approached in writing with the above documentation with a view to arranging a hand-over date.
4. On completion of the Contract, the Contractor shall provide the Engineer with a complete and signed Certificate of Compliance for Electrical Installations as required by the Occupational Health and Safety Act as amended.
29.0 TESTING AND COMMISSIONING DOCUMENTATION
On completion of the Electrical installation and after testing and commissioning, a set of documents shall be compiled and presented to the Engineer. This set shall include the following: 1. CAD copy of all drawings marked up “as built” 5. Completed set of workshop drawings. 6. Completed set of test and commissioning sheets. 7. Set of schematic wiring and function diagrams 8. File of distribution board legends. 9. Operating and maintenance instructions on all electrical equipment.
Testing and commissioning of the LV installation shall be in accordance with the local Municipality requirements.
30.0 COMPLETION OF INSTALLATION
Before the commencement of any tests or commissioning procedures, the Contractor is to ensure that all nuts and bolts are securely fastened, and that paintwork on all items supplied has been touched up where damage has occurred.
31.0 AS BUILT DRAWINGS
The Contractor shall submit to the Engineer a complete set of accurately marked-up, cad drawings of all services installed at completion. The drawings shall be on cad, a hard copy of each drawing shall be submitted as well as a compact disk containing relevant drawing titles.
BILLS OF QUANTITIES FOR PART 2
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: Page No. 2
BOQ FOR PART BILLS OF QUANTITIES 1. The Bills of Quantities form part of the Contract Documents and shall be read in conjunction with the JBCC
Principal Building Agreement as referred to in Part 1, the Preliminaries (Principal Building Agreement) and the Project Specification, Part 4 contained in this document.
2. The Bills of Quantities include as far as can be determined every class of operation, construction or
material that the Sub-Contractor is likely to be called upon to perform or supply. 3. The numbers and quantities set out in the Bills of Quantities are estimated only, and their accuracy on
inaccuracy shall in no way effect the validity of the tender or any contract based thereon. The Sub-Contractor will be required to undertake whatever quantities may be specified from time to time by the Engineer, at the tendered unit prices.
4. The prices and rates to be inserted in the Bills of Quantities are to be inclusive values of the work
described under the several items including all costs and expenses which may be required in and for the construction of the work described, together with all general risks, liabilities, and obligations set forth or implied in the documents on which the tender is based. A price or rate is to be entered against each item in this Bills of Quantities.
5. Should there be any doubt or obscurity, as to the meaning of any particular item, the Tenderer must obtain
an explanation of it in writing from the Engineer. No claims for extras arising from such doubt or obscurity will be admitted after delivery of the Tender.
6. In these Bills, items against which "Provisional Sums" are allowed are intended to provide for special
works and operations either anticipated or problematic, the scope and extent of which cannot be forecast. The "Provisional Sums" allowed will be used as decided by the Engineer, for these works to be carried out under the contract at applicable schedule rates or on a daily basis or alternatively the Engineer may decide to utilize these "Provisional Sums" for carrying out this work by some other contractor subject to the approval of the Employer.
7. Where any discrepancy exists between the unit price and the extended total against any item, the
discrepancy will be adjusted by altering the unit price filled in against such item but not the total tendered sum. In their own interest Tenderers should make double sure about the correctness of their schedule rates (and the extensions) and the Tender Price.
8. All unit prices, extensions and totals must be filled in, in black ink in these Bills of Quantities. 9. All prices shall be quoted in the currency of the Republic of South Africa. 10. All items in the Bills of Quantities shall EXCLUDE 14% Value Added Tax. 11. All items for materials shall include all material including smaller items required or installation such as
cable compound, lugs ferrules, nuts, bolts, etc. 12. All items for installation shall include all the labour required for the complete installation of the item using
the materials as required. 13. The quantities indicated in these Bills of Quantities for cables, earth conductors and excavations shall not
be assumed to be accurate and will be re-measured on site after completion of their installation. Adjustments will be made in accordance with the unit prices indicated in the Bills of Quantities.
14. All measurements shall be based on net quantities and the Tenderer shall make allowance for wastage in
the unit prices.
WCS 045933
Electrical Installation
A - Braamfontein NHLS laboratory
A - BILL NO.1: GENERAL
Item Description Unit QTY Material Labour Amount
1,1 FIXED CHARGE & VALUE RELATED ITEMS
Contractual requirements
Establishment of facilities on site sum 1 -R
1 Office Equipment sum 1 -R 2 Store sum 1 -R 3 Tools & equipment sum 1 -R 4 Services, communications and access sum 1 -R 5 Other sum 1 -R 6 Removal of site establishment on completion sum 1 -R
1,2 TIME - RELATED ITEMSContractual requirementsOperation & maintenance of facilities on site
1 Office Equipment sum 1 -R 2 Store sum 1 -R 3 Tools & equipment sum 1 -R 4 Services, communications and access sum 1 -R 5 Other sum 1 -R
1,3 ADMINISTRATIVEInsurance sum 1 -R Cost of Guarantee sum 1 -R Financing of Retention sum 1 -R Company & head office overhead costs sum 1 -R
1,4 GENERAL COSTS1 Setting out of Works. sum 1 -R 2 Manuals as per specification sum 1 -R 3 Issuing Cadded "As Built" drawings sum 1 -R 4 Inspection and handing over. sum 1 -R 5 Compliance with main contractors P&G's sum 1 -R 6 Issue a certificate of compliance sum 1 -R 7 Test and commissioning of entire electrical installation. sum 1 -R 8 Labelling of SSO's to clearly indicate UPS supply on SSO's sum 1 -R
Total for A - Bill No. 1 Carried forward to summary page -R
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WCS 045933
Electrical Installation
A - BILL NO.2 : LV ELECTRICAL RETICULATION
Item Description Unit QTY Material Labour Amount2,1 MAIN LV CABLES
Supply and installation of PVC/SWA/PVC copper cables to SANS 0150, in
the Following Sizes:Mains Cables
2.1.1.1 Cable from generator changeover to DB-LAB; 50mm² X 4 Core (Armoured) m 50 -R
2.1.1.2 Cable from DB-LAB to UPS to DB-LAB/UPS; 50mm² X 4 Core m 30 -R
2.1.1.3 Cable from DB-LAB/UPS to DB-AC; 35mm² X 4 Core m 20 -R
2.1.1.4 6mm2 X 4 Core m 5 -R
2.1.1.5 4mm2 X 4 Core m 5 -R
2.1.2. Termination of LV cable as specified including connectionof conductors, cable lugs, captive gland, shrouds, etc. Mains Cables
2.1.2.1 50mm² X 4 Core ea 6 -R
2.1.2.2 35mm² X 4 Core ea 2 -R
2.1.2.3 6mm² X 4 Core ea 2 -R
2.1.2.4 4mm² X 4Core ea 2 -R
2.1.3 Earthing Supply and install the following stranded copper earth conductors:
2.1.3.1 35mm² BCEW m 80 -R 2.1.3.2 25mm² BCEW m 15 -R 2.1.3.3 4mm² BCEW m 10 -R
2.1.4 Terminations of earth conductors 2.1.4.1 35mm² BCEW ea 6 -R 2.1.4.2 25mm² BCEW ea 2 -R 2.1.4.3 4mm² BCEW ea 4 -R
Total carried forward to next page -R
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WCS 045933
Electrical Installation
Item Description Unit QTY Material Labour AmountTotal brought from the previous page -R
2,2 DISTRIBUTION BOARDS & SWITCHGEARSupply and Installation of distribution boards as specified and
drawn on schematic diagrams and in positions as indicated on the relevant
drawings. Label all circuits and provide laminated legend card2.2.1.1 DB - LAB (Schematic: C2206 E1 SLD 002 R1) item 1 -R
2.2.1.2
SSO Control Panel complete with switches, indication lamp, and power supplies if
required. As per Sketch A1 (Drawing: C2206 E1 01 001 R1) item 1 -R
Supply and install circuit breakers on different existing distribution boards or
Minisub. The labour rate to include metalwork for preparing the face plate for
installation of the new breakers where necessary. COC to be submitted for the
new breaker circuit only.
2.2.1.3 Supply and install a 160A, 400V, 15kA circuit breaker. ea 1 -R
2.2.1.4 Supply and install a 63A, 400V, 5kA circuit breaker. ea 1 -R
2,3 Sleeves
Supply and install PVC sleeves in ground or cast in concrete.
2.3.1 110mm diameter PVC sleeve m 20 -R
2.3.2 50mm diameter PVC sleeve m 20 -R
2.3.3 32mm diameter PVC sleeve m 50 -R
Total for A - Bill No. 2 Carried forward to summary page -R
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WCS 045933
Electrical Installation
A - ELECTRICAL INSTALLATION (General)
Item Description Unit QTY Material Labour1 INSTALLATION - GENERAL
The following shall apply to all material and equipmentsupplied and installed on site and shall conform to the ElectricalProject specifications contained in this document.
1,1 WIRING CHANNEL Galvanised metal channel complete with covers fixedat intervals not exceeding 1.5m. Channel to be completewith all splices, bends, T-pieces, ends etc.
1,2 CONDUITS & DRAW BOXESGalvanised conduit chased into brickwork,fixed in partitioning, roof spaces, surface on concreteor brickwork to be complete with saddles, couplingsand terminations to drawboxes.Draw boxes to be galvanised type.All cutting and terminations to be included.
1,3 LIGHT FITTINGSTake delivery of, store, install and connect all light fittingscomplete with lamps, gear, etc. as specified and indicated on the drawings. All fluorescent lamps to be of the Triphosphor type and Colour 840 unless indicated otherwise.
1,4 CONDUCTORSSANS approved PVC insulated copper conductors drawninto conduit, installed in wiring trunking or power skirting.
1,5 SOCKET OUTLETS16A, 3-pin switched socket outlets flush mounted in drawboxes complete with cover plates shall beof the "Crabtree "or "Clipsal" range which fit into standard outlet boxesdedicated outlets shall have a red cover platePower Poles shall be of the Cabstrut range type or similar
1,6 LIGHT SWITCHES16A light switch flush mounted in draw boxes or power skirting complete with cover plates shall be of the "Crabtree" or "Clipsal"range which fit into standard outlet boxes.
1,7 DISTRIBUTION BOARDSSupply & Install Distribution Boards complete as in accordancewith the specification and drawings.
1,8 ISOLATORSIsolators surface/flush mounted in 100 x 100mm x 50mmdraw boxes complete with coverplate as specified andindicated on drawings. All isolators installed externally shall be IP 65rotary lockable type
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Electrical Installation
A - ELECTRICAL INSTALLATION (GENERAL)
Item Description Unit QTY Material Labour Amount
1,9 LOW VOLTAGE CABLES600/1000V PVC/SWA/PVC Cables with copper conductors
to SANS 1507 fixed vertically or horizontally on cable trays or installed in sleeves in ground in accordance with the specification and drawings. All fixings to be included.
1,10 TERMINATIONSTermination of LV cable to be as specified includingconnection of conductors, cable lugs, captive coneglands, shrouds, etc. for the relevant cable sizes.
1,11 POWER SKIRTING - GENERAL
Two or one compartment PVC power skirting installed on walls at floor or at levels specified on drawings and specification complete with corners,splices and caps and fixings as specified and shown on drawings.
1,12 MEDIUM WELDED WIRE MESH CABLE TRAYS Medium duty welded wire mesh cable trays complete with fixingsat intervals not exceeding 1.5m. Cable tray to be completewith all splices, bends, T-pieces, ends etc.
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WCS 045933
Electrical Installation
A - BILL No. 3 : ELECTRICAL INSTALLATION - SMALL POWER
Item Description Unit QTY Material Labour Amount
3,1 WIRING CHANNELSupply & Install
3.1.1 P9000 + Cover (127mm x 76mm) m 45 -R 3.1.2 P9000 Horizontal Bend ea 4 -R 3.1.3 P9000 Vertical Bends ea 6 -R 3.1.4 Hangers or Fixing for P9000, complete ea 30 -R
3,2 MEDIUM DUTY CABLE TRAYSupply & Install
3.2.1 200mm wide x 50mm high medium duty cable trays m 65 -R 3.2.2 Horizontal bends ea 6 -R 3.2.3 Vertical Bends ea 3 -R 3.2.4 Cable tray fixing ea 43 -R 3.2.5 Reducing splice: 200mm wide tray to 100mm wide tray ea 1 -R
3.2.5 100mm wide x 50mm high medium duty cable trays m 15 -R 3.2.6 Horizontal bends ea 2 -R 3.2.7 Vertical Bends ea 1 -R 3.2.8 Cable Tray Fixing ea 10 -R
3,3 ConduitSupply and Install
Galvanised conduit installed on surface in roof space, chased into brick work and
fixed surface onto brick walls in the following sizes
3.3.1 25mm - Installed on surface or in ceiling space m 15 -R 3.3.2 25mm - Chased into walls m 5 -R
Outlet BoxesSupply and InstallDraw- and outlet boxes installed surface, in ceiling spaces or chased into brickwalls, in the following sizes:
3.3.1 100mm x 100mm x 50mm deep galvanized steel draw box - Installed on surface ea 6 -R
3.3.2
100mm x 100mm x 50mm deep galvanized steel draw box - Chased into
brickwork ea 1 -R 3.3.3 Galvanised 60mm round , 2-way ea 3 -R 3.3.4 Galvanised 60mm round , 3-way ea 3 -R
3.3.5 100mm x 50mm x 50mm deep galvanized steel draw box - Installed on surface ea 1 -R
3.3.6 100mm x 50mm x 50mm deep galvanized steel draw box - Chased into brickwork ea 1 -R
3.3.7 300mm x 300mm x 75mm drawbox with a lid ea 2 -R 3.3.8 16mm PVC mini-duct m 5 -R 3.3.9 25mm PVC mini-duct m 5 -R
3,4 POWER SKIRTING
Supply and Install
3.4.1
One compartment PVC power skirting complete with Covers, surface mounted to
wall at floor level or at 300mm above finished floor level m 15 -R 3.4.2 Corner - 90deg. Internal ea 3 -R 3.4.3 End Caps ea 2 -R
Total carried forward to next page -R
Page 55
WCS 045933
Electrical Installation
A - BILL No. 3 : ELECTRICAL INSTALLATION - SMALL POWER
Item Description Unit QTY Material Labour AmountTotal from previous page -R
3,5 SOCKET OUTLETSSupply and Install
3.5.1 16A, 3-pin switched socket outlet installed on surface in roof space ea 1 -R
3.5.2 16A, 3-pin double switched socket outlet installed on surface ea 1 -R
3.5.3 16A, 3-pin switched socket outlet installed in power skirting ea 27 -R
3.5.4
200A, 5-pin heavy current industrial male socket outlet and female coupler,
female mounted surface on cradle and male on UPS supply cable. ea 1 -R
3.5.5
200A, 5-pin heavy current industrial female socket outlet and male coupler, male
mounted surface on cradle and female on UPS load cable. ea 1 -R
3,6 SERVICE INSTALLATION REQUIREMENTS
ISOLATORS
Supply & Install the following sizes:
3.6.1 20A TP isolator ea 1 -R
3.6.2 32A TP isolator ea 42 -R
3,7 CONDUCTORSSupply and Install
3.7.1 4mm² stranded PVC insulated with copper conductors m 380 -R
3,8 SURFIX CABLE (BLACK)Supply and Install
3.8.1 4mm² 4-core + earth m 10 -R
Total for A - bill 3 carried forward to summary page -R
Page 56
WCS 045933
Electrical Installation
A - BILL No.4 : ELECTRICAL INSTALLATION - LIGHTING
Item Description Unit QTY Material Labour Amount
4,1 ConduitSupply and InstallGalvanised conduit, installed chased in walls, in open roof spaces and fixed surface on the wall in the following sizes:
4.1.1 20mm diameter conduit - Installed on surface or in ceiling space m 50 -R
Outlet BoxesSupply and InstallGalvanised steel draw and outlet boxes installed surface, in ceiling spaces or chased into brickwalls, in the following sizes:
4.1.2 100mm x 50mm x 50mm deep galvanized draw box - Installed on surface ea 1 -R 4.1.3 60mm round , 2-way ea 8 -R 4.1.4 60mm round , 3-way ea 4 -R 4.1.5 5A unswitched socket outlet ea 1 -R
4,2 Light Switches(Complete with Cover Plates)Supply and Install
4.2.1 16A 1 Lever - 1 Way switch, flush in draw box ea 1 -R 4.2.2 16A 3 Lever - 1 Way switch, flush in draw box ea 1 -R
4,3 LIGHT FITTINGS
Take delivery, store, supply & install the following light fittings with lamps &
including the necessary framework etc. All as specified and indicated on the
drawings. All fittings shall comply to the requirements of the South African
National Standards. All light fittings will be inspected by the Engineer and if found
not to comply with the minimum requirements of the above Institution, will be
replaced at the expense of the tenderer.
4.3.1
Type F1, as specified. 2X36W vapourproof fluorescent fitting with die cast
aluminium body complete with electronic ballasts and rotolock lamp holders.
Surface of the fitting to be smooth and diffuser to be one-piece injection moulded
clear polycarbonate vandal resistant, secured to the body with 6xstanless steel
Allen head screws. Body designed to prevent dust build-up. ea 4 -R
4.3.2
Type F2, as specified. 2X18W vapourproof fluorescent fitting with die cast
aluminium body complete with electronic ballasts and rotolock lamp holders.
Surface of the fitting to be smooth and diffuser to be one-piece injection moulded
clear polycarbonate vandal resistant, secured to the body with 6xstanless steel
Allen head screws. Body designed to prevent dust build-up. ea 3 -R
4,4 CONDUCTORS
4.4.1 2.5mm2 PVC insulated with copper conductors m 120 -R
4.4.2 2.5mm2 insulated copper earth conductor m 60 -R
Total for A - bill 4 carried forward to summary page -R
Page 57
WCS 045933
Electrical Installation
A - BILL No.5 : ELECTRICAL INSTALLATION - Electronic Services
Item Description Unit QTY Material Labour Amount
Supply & Installation of the following:
5,1 CONDUIT (Access Control)
Galvanised conduit fixed to surface, installed chased in walls and in open roof
spaces in the following sizes
5.1.1 32mm2 diameter conduit - Installed on surface or in roof space. m 40 -R
5.1.2 25mm2 diameter conduit - Chased into brickwork or walls m 15 -R
5.1.3 1.6mm2 steel draw wire m 50 -R
5,2 OUTLET BOXES (Access Control)
Galvanised steel draw and outlet boxes installed surface
or chased into brickwalls, in the following sizes:
5.2.1 100mm x 100mm x50mm deep box, surface, with blank coverplate ea 3 -R
5.2.2 100mm x 50mm x50mm deep box, surface, with blank coverplate ea 6 -R
5.2.3 60mm round box, 2-way - Installed on surface or in roof space ea 15 -R
5.2.4 60mm round box, 3-way - Installed on surface or in roof space ea 7 -R
5.2.5 230mm x 230mm x 75mm drawbox with a lid ea 1 -R
5,3 PVC Mini-Duct
5.3.1 16mm PVC mini-duct m 5 -R
5.3.2 25mm PVC mini-duct m 5 -R
5,5 Access control installation
5.5.1
Provisional sum:
Supply and install complete access control installation as per specifications. sum 1 65 000,00 65 000,00R
5.5.2 Profit and attendance on the above %
Total for A - bill 5 carried forward to summary page -R
Page 58
WCS 045933
Electrical Installation
Item Description Amount
1 TOTAL FOR BILL NO. 1 -R 2 TOTAL FOR BILL NO. 2 -R 3 TOTAL FOR BILL NO. 3 -R 4 TOTAL FOR BILL NO. 4 -R 5 TOTAL FOR BILL NO. 5 -R
-R
1
2 Above amounts to exclude VAT.
A - SUMMARY OF BILLS OF QUANTITIES
Above amounts to be carried forward to the Tender Summary Page of the Principle Contract contained in Volume 1
and 2 of the Tender Document.
TOTAL FOR ELECTRICAL INSTALLATION (Excl. VAT) TO BE CARRIED FORWARD TO PART 1 -PRICE BREAKDOWN
SCHEDULE : SCHEDULE 4
Page 59
Bill : Access Control Installation
Item Description Unit QTY Supply Install Amount
Supply & Install the following equipment including all connectors, terminal screws:
2,1 Head End
2.1.1 Entry level server/PC as specified No 1 -R
2.1.2 Access Control software as specified No 1 -R
2.1.3 Webcam, complete with software for enrolment No 1 -R
2.1.4 On-line printer No 1 -R
2.1.5 Programming No 1 -R
2.1.6 Access Control Master Controller No 1 -R
2,2 Field Equipment
2.2.1 Magnetic door contacts No 2 -R
2.2.2 Biometric/Card readers No 2 -R
2.2.3 Industrial push button No 2 -R
2.2.4Door/Access controllers complete as specified including power
supply and 7Ah battery No 1 -R
2.2.6 Door closers No 2 -R
2.2.7 Proximity cards – Tags No 15 -R
2.2.8 Electro magnetic lock No 2 -R
2.2.9 Door loops No 2 -R
2.2.10 Local sounders at monitored doors No 1 -R
2,3 Cabling
2.3.1 Multi core cabling as specified m 150 -R
2,4 Testing and Commissioning
2.4.1 Test and commission the complete system as specified. No 1 -R
2,5 Sundries
2.5.1 Any additional items to conform to specification : Sum 1 -R
Please list them:
Total for Bill Access control carried forward toPart 1 Price breakdown schedules : Schedule 4 (Excl. VAT): -R
PART 3 GENERATOR PROJECT SPECIFICATION
PART 3 GENERATOR PROJECT SPECIFICATION
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INDEX ITEM DESCRIPTION PAGE NO.
1.0 SITE 3
2.0 VISIT TO SITE 3
3.0 BILLS OF QUANTITIES 3
4.0 SCOPE OF CONTRACT 3
5.0 PROGRAMME 9
6.0 WORKMANSHIP 9
7.0 QUALITY OF MATERIAL 9
8.0 INSPECTION AND TESTING 10
9.0 TESTING AND COMMISSIONING DOCUMENTATION 10
10.0 COMPLETION OF INSTALLATION 11
11.0 AS BUILT DRAWINGS 11
12.0 SCHEDULES OF TECHNICAL INFORMATION 11
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PROJECT SPECIFICATION
1.0 SITE
The site is located on the corner of 22 Hospital street, Braamfontein,Johannesburg 2017. 2.0 VISIT TO SITE
Tenderers shall acquaint themselves with local site conditions such as access to the site, size and type of site, type of ground, supply of labour, workshop space, transport, loading and unloading facilities, scaffolding, tackle and tools needed for the erection of the installation. Additional claims by the Sub-Contractor, which may arise from ignorance of the site conditions, will not be considered and Tenderers are required to visit and inspect the site in the company of the engineer for a formal site visit. Refer to the principal contract for the site inspection.
3.0 BILLS OF QUANTITIES
Included in this document is a bill of quantities for every type of operation which may occur during the execution of the generator installation. As part of their submission, tenderers must complete this bill of quantities.
The rates supplied in this bill shall be fixed for the duration of the contract and be nett, excluding VAT. The rates for the supply and installation shall be inclusive of small items, such as screws, washers, etc.
These rates shall be used in the adjudication of the electrical tenders.
4.0 SCOPE OF CONTRACT
The following scope of work is included in this contract:
This specification covers the complete design, manufacture, works testing, delivery to site, rigging into position, installation on site, commissioning and documentation of the standby generator installation at the Aerosol Laboratory, Braamfontein, to the Electrical Subcontractor’s and Electrical Engineer’s satisfaction.
4.1 GENERAL
1.1 The Diesel-Alternator plant shall be fully automatic, i.e. it shall start when the main electricity
supply fails and shut down up to 5 minutes after restoration of the normal supply and shall comply with BS 649.
1.2 The Specialist Supplier of the diesel alternator plant shall be responsible for the design,
manufacture, works testing, delivery to site, rigging into position, complete installation on site including cabling between the generating set, ancillary equipment and switchboard and commissioning of the plant and equipment specified herein.
1.3 Full particulars and detailed drawings of the equipment offered must be submitted with the
tender.
1.4 The installation shall comply in its entirety with the regulations of the “Occupational Health & Safety Act of 1993” as amended to date, and, with all other regulations and specifications governing the works.
1.5 The combined engine and alternator shall be mounted together on a common channel iron
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base frame incorporating anti-vibration mounts and enclosed in a sound and weather proof enclosure. The enclosure is to be 3 CR12 stainless steel and powder coated as specified.
1.6 All exposed moving parts including the flexible coupling shall be protected by suitable guards
which shall be easily removable for maintenance purposes.
1.7 A full set of tools for general routine maintenance of the plant shall be provided in a suitable lockable cupboard. A complete list of the tools offered must be submitted with the tender.
1.8 Tenderers shall include for spare parts recommended for 250 hours operation of the plant.
Individual prices of spares shall be quoted.
1.9 The Standby Generator Contractor shall, within 30 days of being awarded the contract, provide for the Engineer’s approval final switchboard schematic and wiring diagrams, including emergency shut down panel, and fully detailed sequence of operations. In addition to the above a drawing indicating the exhaust run and ventilation requirements must be provided by the Standby Generator Contractor. It will be the standby generator contractor’s responsibility to ensure that adequate ventilation with regard to noise and exhaust emissions. All costs in this regard must be allowed for by the tenderer.
1.10 The Standby Plant Generator Contractor shall supply to the Engineer before hand-over, three
copies each of all drawings and operating maintenance and spares manuals covering the complete plant.
1.11 The Standby Generator Contractor will be required to service and maintain the plant for the 12
month guarantee period after which date maintenance will be handed over to the Client. The contractor must make four quarterly visits to the plant for this purpose and submit a service report to the client on completion of the respective service. A copy of the proposed service activities that will be carried out at each service visit must be submitted with this tender.
1.12 Generator shall be supplied complete with powder coated mild steel canopy, complete with
sound proofing and lockable latch access and service doors. 1.13 Tenderers shall ensure that the Generator’s Alternator Voltage Regulator can withstand
the full UPS load at 100% and that the alternator will endure the high harmonic load from the UPS.
4.2 DIESEL ENGINE
2.1 The engine shall be multi-cylinder, vertical or inclined, solid injection, compression ignition type
running at a speed not exceeding 1 500 rpm at rated output.
2.2 The engine may be air or water cooled and the latter type shall have a heavy duty, built-in, tropical type radiator fitted.
2.3 An air-cooled engine should have a positively driven fan.
2.4 The engine shall be equipped with:
- A governor controlling the speed of the engine in accordance with Clause 5 of BS 649, to
Class A. - Flywheel of dimensions such that cyclic irregularity is to Clause 9 of BS 649.
2.5 The nominal speed of the engine shall be adjustable by external manual control.
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2.6 The engine shall have the following minimum protective devices which will shut it down under the following conditions:
a) High engine temperature (measured in oil or directly in engine
block) b) Low oil pressure c) Over-and-under speed d) Low radiator water level
2.7 The engine shall be easily started from cold without the use of any special ignition devices
under all weather conditions. For water cooled engines a thermostatically controlled 230V 50Hz jacket water heater must be provided. To facilitate element replacing valves must be provided in the heater feeds so that the cooling water of the engine does not have to be drained when this takes place.
2.8 An axial type electric starter motor shall be supplied fitted to the engine.
2.9 The starter motor will cease to crank the engine immediately firing commences.
2.10 Should the normal power supply fail while the engine is shutting down the starter will not
engage until the engine is at rest.
4.3 FUEL SYSTEM
3.1 The fuel tank is to be incorporated into the base of the genset and hold sufficient fuel for 12 hours continuous operation at full load. A stand mounted, ungalvanised steel, all welded, dust & weatherproof fuel tank shall be provided for Edgars/Jet and C.N.A/Legit sets.
3.2 A small manually operated semi-rotary pump for mounting near the fuel tank with sufficient suction hose to reach from the pump to the open parking area, shall be provided.
3.3 Fuel injection equipment shall be suitable for diesel fuel complying with SABS 342.
3.4 The filter shall be reliable and of sufficient capacity for the size of the engine. The element shall be disposable and filter down to 5micron particle size.
4.4 LUBRICATION
4.1 A pressure feed system shall be incorporated in the engine and shall have a disposable
element filter suitable for detergent type lubricating oils fitted between the pump and engine circuit.
4.2 A bypass shall be incorporated whereby the lubricating oil supply to the engine shall continue
if the filter is choked.
4.3 An oil pressure gauge shall be fitted with all the necessary attachments. 4.4 The engine bearings such as crankshaft, small and etc shall be of bush or split-sleeve type
capable of operating effectively under the above conditions.
4.5 EXHAUST SYSTEM 5.1 The engine shall be fitted with a suitable exhaust system having the following:
5.1.1 Robust effective exhaust silencer of the “Burgess” type.
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5.1.2 Suitable heat insulation lagging of the non asbestos type must be provided along the exhaust run where the exhaust is within reach.
5.1.3 Tenderers shall allow for 3000mm of exhaust piping. 5.1.4 The silencer shall be suitable for a residential area.
4.6 ALTERNATOR
6.1 The alternator shall be of the self-excited, inherently self-regulated, screen protected, drip-
proof type. 6.2 The alternator winding insulation shall be in accordance with BS 2757 Class H. 6.3 For continuous full load operation of the alternator under rated conditions the temperature rise
shall not exceed the limits stated in BS 2613. 6.4 The percentage rise in terminal voltage when full rated load at 0,8 power factor is removed,
variations in engine speed notwithstanding, shall not be greater than 5%. 6.5 With instantaneous application of full load from the no-load condition the voltage drop must not
exceed 10% and recovery to rated voltage must be within 300 milli seconds. 6.6 The neutral of the alternator shall be solidly earthed to the substation, supply authority or
building earth.
4.7 BATTERY 7.1 Where electric starting is employed, the combination engine generator set shall be equipped
with fully charged lead-acid maintenance free batteries with the following requirements:
7.1.1 The batteries shall be mounted on a suitable corrosion proof rack.
7.1.2 The battery shall have ample capacity for providing the starting torque stipulated by the engine manufacturer and capacity for 6 such starts in a five minute period.
7.1.3 The battery shall be supplied with a charger unit as described below.
4.8 BATTERY CHARGER
8.1 The switchboard detailed in Clause 9 below shall contain facilities for charging the batteries
from the mains. 8.2 The battery charger shall be of the fully automatic type and shall consist of an air cooled
transformer, silicon bridge rectifier, fuses and switching arrangement. All equipment shall be suitably rated and designed to automatically deliver a trickle or boost charger as determined by the battery voltage. The boost charge in amps shall not exceed 20% of the rated battery capacity.
8.3 A consistent trickle charge facility is not acceptable. The charger shall switch off automatically
when the battery is fully charged. 8.4 The charger must be provided with a voltmeter and charge ammeter. These instruments must
be mounted on the control panel door.
4.9 SWITCHBOARD/CONTROL PANEL 9.1 A switchboard/control panel must be provided for the control, metering and switchboard of the
diesel alternator set.
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9.2 Fault level The board and its equipment shall be rated at not less than the 400V asymmetrical prospective fault level specified in the detailed specification. 9.3 The switchboard shall consist of steel panels supported on a substantial angle iron framework
and shall be supplied with all the equipment necessary for the control and protection of the plant, automatic changeover and battery charging.
9.4 All the equipment shall be mounted behind the front panels on suitable supports and shall be
easily accessible. 9.5 The front panels shall be either hinged or held in position by means of captive thumb screws. 9.6 The steelwork of the switchboard shall be thoroughly de-rusted, primed with zinc-chromate
and finished with two coats of first class approved enamel paint or powder coated. The colour of the switchboard shall be signal red.
9.7 Suitable rated and clearly marked terminals shall be provided for the incoming mains, the
outgoing feeder, the battery circuit and the protective circuits. 9.8 The switchboard shall be fully wired internally. Busbars of adequate capacity shall be
provided. All wiring shall be identified by means of approved labels. 9.9 The switchboard shall be fitted with the following: 9.9.1 A triple pole circuit breaker with instantaneous short circuit trips and thermal overload trips.
The overload trips set to the relevant alternator full load current. 9.9.2 A four position selector switch to select the following operations.
AUTO, fully automatic operation. Light on switchboard/control panel to show when in AUTO position.
MANUAL, the set can be started and stopped using a suitable push button on the switchboard. The set will take the load when started thus but it must NOT be possible to close the set onto live mains or live mains on to the set.
TEST, the set can be started and stopped as in above but will not take load.
OFF, positions shall de-energize all control circuits and shall be lockable by means of a small padlock in this position. Two keys shall be provided with the padlock.
9.9.3 Eight relays each with illuminated reset pushes to give a visual and an audible signal on operation of a protective cutout. Relays shall operate a small hooter which shall be powered by the starter batteries. All signaling circuits shall likewise be supplied from these batteries. Terminals shall be provided on the switchboard connected to the alarm relays and the hooter circuit, suitable for remote indication of the alarms.
9.9.4 Illuminated reset pushes suitable labeled to indicate the following alarm/shutdown conditions
START FAILURE (alarm)
LOW ENGINE OIL PRESSURE (trip)
HIGH ENGINE TEMPERATURE (trip)
OVER/UNDERSPEED (trip)
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LOW RADIATOR WATER LEVEL (trip)
BATTERY CHARGER FAILURE (alarm)
LOW FUEL (alarm)
NOT ON AUTO (alarm) 9.9.5 One flush 100mm square dial voltmeter, suitably scaled and marked “Alternator Voltage”. 9.9.6 One seven position voltmeter selector switch. 9.9.7 One flush 100mm square vibrating type frequency meter, marked “Alternator Frequency”. 9.9.8 One hour-meter with cyclometer counter, marked “hours operated”. The counter shall read to
9999,9 hours. 9.9.9 One set of suitably rated fuses for potential circuits of meters. 9.9.10 Three flush 100mm square maximum demand and indicating dial ammeters suitable scaled for
the relevant alternator full load current each with air cooled current transformer. 9.9.11 One mains failure relay to provide a mains failed signal. This relay is t detect failure of any
phase of the normal mains supply or phase rotation reversal of that supply. 9.9.12 Two push buttons marked ‘START’ and ‘STOP’ for manual stop/start of set. 9.9.13 One set battery charger equipment as noted. 9.9.14 One flush ammeter suitably scaled marked “charging current”. 9.9.15 One voltmeter, suitably scaled marked “battery voltage”. 9.9.16 Adjustable timers for the following functions; Start delay 0-20 seconds On load run 0-10 minutes Off load run 0-10 minutes 9.9.17 Eight relays with illuminated re-set buttons. 9.9.18 One 1 kilometer siren. 9.9.19 Suitable terminals as required. 9.9.20 1 x TP isolator (sized to suit relevant generator set output) for mains supply isolation 9.9.21 2 x TP changeover contractors rated for the generator output to AC-3, mechanically &
electrically interlocked 9.9.22 2 x TP MCB (sized to suit relevant generator output set) for switching and protection of the
generator output. 9.9.23 Prefitted space for - 2 x TP MCB’s rated for applicable fault level - 2 x TP MCB’s rated for applicable fault level - 1 x 4 point 160A bypass switch - 1 x time switch - 2 x contractors (160A TP AC-3)
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9.9.24 Instruments must be provided on the control board to indicate the following; Engine temperature Engine oil pressure Engine battery charge/discharge
4.10 LABELS &WIRING NOTICES 10.1 Warning notices mounted in a conspicuous position shall be provided on and inside the
canopy which shall be clearly legible and indelible. 10.2 Warning notices shall be made of non-corrodible material, preferably plastic. 10.3 Warning notices shall read as follows: “EMERGANCY STANDBY PLANT” This engine will start without warning 10.4 All titles, notices, labels etc on the switchboard or elsewhere on the equipment shall be in
English. Canopy warning notices in accordance with OHS Act.
5.0 PROGRAMME
The Tenderers’ price should be based on the following programme:
The building project construction period shall extend over a period of approximately four months. The Sub-Contractor will perform his installation in accordance with the Main Contractor’s overall construction Programme.
6.0 WORKMANSHIP
The Sub-Contractor shall employ only competent artisans to perform construction and installation work on the site.
The Sub-Contract shall be executed with the best workmanship in a workmanlike manner to the satisfaction of the ENGINEER. Should any workmanship not be to the satisfaction of the ENGINEER it shall be rectified at the cost of the Sub-Contractor.
The Sub-Contractor shall remain responsible for the correct and complete delivery of the installation. Inspection by the ENGINEER shall not release the Sub-Contractor from his responsibility.
7.0 QUALITY OF MATERIAL
Only material of high quality and suitable for the climatic conditions of the site shall be used and shall be subject to approval by the ENGINEER. All material shall conform in respect of quality, manufacture, tests and performance, with the requirements of the SANS or where no such standards exist, conform to the appropriate current Specification of the British Standards Institution. Materials manufactured in South Africa shall as far as possible be used and where applicable shall bear the SABS mark. Imported
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materials shall comply with the requirements of the appropriate B.S. or I.E.C. specification. All materials shall be suitable for the conditions under which the materials are installed and used. Should the materials or components not be suitable for temporary use under site conditions, the Sub-Contractor shall at his own cost provide suitable protection until these unfavourable site conditions cease to exist.
8.0 INSPECTION AND TESTING On completion of the entire installation or any particular section thereof, as may be decided by the Engineer, tests shall be carried out in full accordance with the current edition of SANS 10142-1, the “Code of Practice for the Wiring of Premises”, in the presence of the Engineer or his authorized Representative. The Contractor should note that where applicable at least the following tests must be carried out:
Generator Installation
1. Full load, 60% load and 40% load factory test witnessed by the Engineer or one of his
representatives. 2. At the supplier’s premises, before the generating set will be delivered to site Representatives of
the Client and Engineer may be present during the test to satisfy them that the generating set complies with the specification and delivers the specified output. The Client must be timeously advised of the date for the test.
3. After completion of the works and before first delivery is taken, a full test will be carried out on the
installation for a period of sufficient duration to determine the satisfactory working thereof. During this period the installation will be inspected and the contractor shall make good, to the satisfaction of the Representative/Agent, any defects which may arise.
4. The Contractor shall provide all instruments and equipment required for testing and any water,
power and fuel required for the commissioning and testing of the installation at completion. 5. Test reports of both tests as specified under (a) and (b) are to be submitted to the Department. Note:
1. All instrumentation necessary for testing shall be provided by the Sub-contractor. 2. The results of the above tests must be clearly recorded, signed and handed to the Engineer. 3. Once the Engineer has inspected the complete installation and satisfied himself that all testing has
been completed and the Sub-Contract is complete in all respects, may the Engineer be approached in writing with the above documentation with a view to arranging a hand-over date.
4. On completion of the Contract, the Contractor shall provide the Engineer with a complete and signed Certificate of Compliance for Electrical Installations as required by the Occupational Health and Safety Act as amended.
9.0 TESTING AND COMMISSIONING DOCUMENTATION
On completion of the Electrical installation and after testing and commissioning, a set of documents shall be compiled and presented to the Engineer. This set shall include the following: 1. Completed set of workshop drawings. 2. Completed set of test and commissioning sheets. 3. Set of schematic wiring and function diagrams 4. Operating and maintenance instructions on all equipment.
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Testing and commissioning of the generator installation shall be in accordance with the local DPW requirements.
10.0 COMPLETION OF INSTALLATION
Before the commencement of any tests or commissioning procedures, the Contractor is to ensure that all nuts and bolts are securely fastened, and that paintwork on all items supplied has been touched up where damage has occurred. The Generator shall be formally handed over to the facility, who will assume responsibility for maintenance of the generator after completion of suppliers 12month maintenance contract.
11.0 AS BUILT DRAWINGS
The Contractor shall submit to the Engineer a complete set of accurately marked-up, schematic drawings at completion. The drawings shall be a hard copy of each drawing shall be submitted as well as a compact disk containing relevant drawing titles.
12.0 SCHEDULES OF TECHNICAL INFORMATION
1. Engine
NO ITEM REMARKS
1. Manufacturer’s Name
2. Country of Origin
3. Manufacturer’s model No. and year of manufacture
4. Continuous sea level rating after allowing for
ancillary equipment :
a) In b.h.p.
b) In kW
5. Percentage de-rating for site conditions, in
accordance with BS 551.4
a) For altitude
b) For temperature
c) For humidity
d) Total de-rating
6. Net output on site in kW
7. Nominal speed in r.p.m.
8. Number of cylinders
9. Strokes per working cycle
10. Stroke in mm
11. Cylinder bore in mm
12. Swept volume in cm3
13. Mean piston speed in m/min
14. Compression ratio
15. Cyclic irregularity
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NO ITEM REMARKS
16. Fuel consumption of the complete generating set on
site in l/h of alternator output at :
a) Full load
b) ¾ load
c) ½ load
NOTE :
A tolerance of 5% shall be allowed above the stated
value of fuel consumption.
17. Make of fuel injection system.
18. Capacity of fuel tank in litres
19. Is gauge glass fitted to tank?
20. Is electric pump for filling the fuel tank included?
21. Method of starting
22. Voltage of starting system
23. Method of cooling
24. Type of radiator if water-cooled
25. Type of heater for warming cylinder heads
26. Capacity of heater in kW
27. Method of protection against high temperature
28. Method of protection against low oil pressure
29. Type of governor
30. Speed variation in %
a. Temporary
b. Permanent
31. Minimum time required for as assumption of full
load in seconds
32. Recommended interval in running hours for :
a. Lubricating oil change
b. Oil filter element change
c. Decarbonising
33. Type of base
34. Can plant be placed on solid concrete floor?
35. Are all accessories and ducts included?
36. Is engine naturally aspirated?
37. Are performance curves attached?
38. Diameter of exhaust pipe
39. Noise level in plant room in dBA N/A
40. Noise level at tail of exhaust pipe in dBA
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NO ITEM REMARKS
41. BMEP (4 stroke) at continuous rating (kPa)
42. % Load acceptance to BS 5514, Part 4, with 10%
transient speed drop
2. Alternator
NO ITEM REMARKS
1. Maker’s name and model no.
2. Country of Origin and year of manufacture
3. Type of enclosure
4. Nominal speed in r.p.m.
5. Number of bearings
6. Terminal voltage
7. Sea level rating kVA at 0,8 power factor
8. De-rating for site conditions
9. Input required in kW
10. Method of excitation
11.
Efficiency at 0,8 power factor and :
a) Full load
b) ¾ load
c) ½ load
12. Maximum permanent voltage variation in %
13. Transient voltage dip on full load
14. Voltage recovery on full load application in milli-
seconds
15. Is alternator brushless?
16. Class of insulation of windings
17. Is alternator tropicalised?
18. Symmetrical short circuit current at terminals n
Ampere
19. Type of Coupling
3. Switchboard
NO ITEM REMARKS
1. Maker’s Name
2. Country of Origin
3. Is board floor mounted?
4. Finish of board
5. Make of volt, amp, and frequency meters
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NO ITEM REMARKS
6. Dial size of meters in mm
7. Scale range of voltmeter
8. Scale range of ammeters
9. Ration of current transformers
10. Make of hour meter
11. Range of cyclometer counter
12. Smallest unit shown on counter (Item 11)
13. Make of circuit breaker
14. Type of circuit breaker
15. Rating of circuit breaker in Amp and fault level in
kA
16. Setting range of overload trips
17. Setting range of instantaneous trips
18. Make of change-over equipment
19. Make of voltage relay
20. Is control and protection equipment mounted on a
small removable panel?
21. Type of control equipment
22. Make of mains isolator
23. Type of indicators for protective devices
24. Make of rectifier
25. Type of rectifier
26. Is battery charging
27. Are volt- and ammeters provided for charging
circuit?
28. Is the alarm hooter of the continuous duty type?
29. Rating in Amps of :
a. Change-over equipment
b. Mains on load isolator
c. By-pass switch
d. Circuit breaker to outgoing feed
30. Is manufacture of switchboard/control panel to be
sub-let?
31.
If yes, state name and address of specialist
manufacturer
4. Battery
NO ITEM REMARKS
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1. Maker’s Name
2. Country of Origin
3. Type of battery
4. Voltage of battery
5. Number of cells
6. Capacity in cold crank amp
5. Dimensions
NO ITEM REMARKS
1. Overall dimensions of set in mm
2. Overall mass
3. Is the generator room adequate for the
installation of the set
6. Deviation from the Specification as An Alternative (State Briefly)
NO DESCRIPTION
7. Spare Parts and Maintenance Facilities
NO ITEM REMARKS
1 Approximate value of spares carried in stock
for this particular diesel engine and alternator
2 Where are these spares held in stock
3 What facilities exist for the servicing of the
equipment offered
4 Where are these facilities available
The Priced Schedule of Quantities must be Net. VAT will be calculated elsewhere and added to the overall contract value.
When the tender is submitted the amounts to be added to or deducted from the quotation amount, according to whether the under mentioned is
The priced schedule shall be checked by the Engineer who shall be at liberty to call for such adjustments of individual prices as he considers
necessary on the basis of the average ruling prices as determined by him for similar work in the industry in the area in which the work is
situated. The method by which the average ruling prices are determined shall be at the sole discretion of the Engineer.
The quantities given in the schedule cannot be regarded as exact and are subject to measurement on site after completion of the service and
adjustments will be made according to the unit rates given in the Schedule. The installation costs shall include all fixing materials and wastage
as well as the disconnection and removal of all obsolete items.
BILLS OF QUANTITIES
PRICE SCHEDULE OF QUANTITIES:
1,1
1,2
1,3
1,4
1,5
1,6
1,7
1,8
1,9
1,1
1,11
1,12
1,13
1,14
1,15
1,16
1,17
1,18
The Tenderers shall allow for scaffolding, ladders, tackle, tools, slings, etc. which may be required in the execution of this subcontract.
Where it is desired to offer alternative prices for equipment, materials, etc. of different manufacture, the price for the equipment to specification
must be quoted against the relevant item in the Bill of Quantities. The alternative prices must be furnished separately and shall comply with the
specification 100%.
Where any item in the Bills of Quantities is listed as a provisional quantity, such items shall be adjusted and agreed to during the course of the sub-
contract. No work for which “Provisional” items are provided shall be commenced without written instructions from the Engineer.
The Tenderer shall notify the Engineer in writing during the tender period of any discrepancies, between the Bills of Quantities & Specification.
Failure to comply with this condition will invalidate any claim arising out of discrepancies in the quantities between the Bill of Quantities and
Specifications and actual quantities allocated to the project.
Tenderers shall note that the total for each page of the bill of quantities shall be carried forward to the summary sheet of the complete bill of
quantities.
It is a requirement of this tender document that all tenderers shall complete the bill of Quantities in full and submit the completed bill of quantities at
tender submission stage. Non-compliance to the above statement shall lead to disqualification.
B - Bill No: 01 PREAMBLE TO BILLS OF QUANTITIES
The quantities indicated in these Bills of Quantities for cables, earth conductors and excavations shall not be assumed to be accurate and will be
remeasured on site after completion of their installation. Adjustments will be made in accordance with the unit prices indicated in the Bills of
Quantities.
The pages of each bill are numbered consecutively as indicated in the contents. Before the Tenderer submits his tender, he should check the
number of the pages and if any are found missing or duplicated, or the figures or writing indistinct, or should the Bills of Quantities contain any
obvious errors, he should apply to the Engineer at once and have same rectified, as no liability whatsoever will be admitted by the Engineer or the
Employer in respect of errors in tender due to the foregoing.
The Bills of Quantities form part of and shall be read in conjunction with the Specification which contains the full description of the work to be done
and material and equipment to be used and unless otherwise described in the Bills of Quantities, reference should be made to the Specification for
the full meaning of descriptions of work to be done and materials and equipment to be used in this service.
All items in the Bills of Quantities shall be priced and submitted at the same time of tendering. Any item left unpriced shall be assumed to be
covered elsewhere in the Bills of Quantities.
Any equipment not priced by the tender in order to deliver a fully operational system shall be for tenderer responsibility.
Variations in the scope and extent of the work included in the bill shall be allowed to meet the requirements and shall be measured and costed at
rates entered in the bill, where appropriate, and shall form an addition to or deduction from the total of the Bill. Any items or variation for which
rates have not been included in the Bill shall be agreed and priced as non-scheduled items.
Variations to be planning before the work has been executed shall be priced as above. Alterations to work already executed cannot necessarily be
priced as above and must be reviewed on its merits.
A separate rate for the supply and for the installation of each item is specifically called for:
1.0 Introduction
The bill of quantity cannot be used for ordering material after appoint. Any equipment or material ordered without prior approval from the relevant
consulting engineer regarding type of equipment, material and quantities thereof, shall be to contractor’s account no claims will be entertained
without copy of approved equipment and quantity. It is the successful tenderer’s responsibility to ensure that the relevant consulting engineer has a
detail copy of equipment that need to be procured for approval timeously to ensure that all lead items and required material is available in time on-
site to meet all relevant milestones. This clause does not relieve the successful tender’s project manager to coordinate all procurements and works
to meet all milestones as stipulated in conditions of contract.
The rates quoted for supply and installation of each item shall, unless otherwise stated herein, be held to include making, conveying and
delivering, unloading, storing, unpacking, hoisting, setting, fitting and fixing in position, cutting and waste, patterns, models and templates, plant,
temporary works, return of packages, establishment charges sundry services, profit and all other obligations arising out of the conditions of
contract.
The total tender price in the tender form shall constitute the contract price of the successful Tenderer. Tenderers are advised to check their item
extensions and total additions, in the Bills of Quantities as no claim for arithmetical errors will be considered.
No alteration, erasure or addition is to be made in the text of the Bill of Quantities. Should any alteration, erasure or addition be made it will not be
recognised but the original wording of the Bill of Quantities will be adhered to.
The priced Bill of Quantities of the successful Tenderer will be checked and the Engineer/Employer reserves the right to call for adjustments to any
individual price and to rectify any discrepancy whilst the total tender price, as submitted, remains unaltered.
The responsibility for the accuracy of the quantities written into the Bills remains with the Engineer and the Employer. The Tenderer shall be
relieved of responsibility of measuring quantities at the tender stage, and the tender sum submitted shall be in respect of the quantities set out in
the Bill, although he will be required to make his assessment of items such as brackets, fixings, etc., from details stated in the Bill and shall include
in the item prices for such small installation materials as are required for the complete installation in accordance with the specification.
ITEM UNIT QTY RATE AMOUNT
1
Item 1
1.1
Item 1
2
m 5
3
m 3
4
Item 1
5
5,1 m 15
6
6,1 each 2
7
7,1 m 15
R
TRUNKING
P 9000 trunking: Supply and install all splices, joints, fixing materials and covers.
EARTHING OF GENERATOR
Supply and install earthling system as required by Regulations.
LOW VOLTAGE SUPPLY CABLES
Supply and install the following 600/1000V PVC/SWA/PVC cables with copper conductors
to SABS 1507 laid vertically or horizontally in conduiting or ducting or clipped direct in
accordance with the specification and drawings, including fixing. (Termination elsewhere).
Supply and Install
DESCRIPTION OCCUPATIONAL HEALTH & SAFETY
B - BILL No. 2: ELECTRICAL INSTALLATION
Allowance for Compliance with Construction Regulations, as detailed in Occupational
Health & Safety Act (OHS), Act 85 of 1993. Submission of a (OHS) plan and all applicable
documentation, to the client’s satisfaction, and in accordance with the Main Contractor’s
H&S requirements.
EXISTING SUPPLY
Disconnect the existing supply and coordinate power down with facility for cable
connection onto 160A circuit breaker located in the minisub.
CABLE LADDER
150mm wide: Supply and install on the floor and on walls, including all splices, joints and
fixing materials
50 mm2 x 4 core (Armoured)
TERMINATIONS
Termination of LV cable as specified including connection of conductors, cable lugs,
captive glands, shrouds, etc. for the following cable sizes.
Supply and install
50 mm2 x 4 core
EARTH WIRES
Supply and install the following 600/1000V conductors and bare stranded copper
conductors on wire ways or trenching including terminations for earthing in accordance
with the specification and drawings.
Supply & Install
35mm2 BCE Wire
AMOUNT CARRIED FORWARD
ITEM UNIT QTY RATE AMOUNT
R
8
Item 0
9
Item 0
10
10,1 m 15
10,2 Item 2
11
11,1 m 15
11,2
m 8
m 5
m 2
11,3 m 5
12
Sum 1
13
Item 1
RTotal Carried to Summary of Bills of Quantities
B - BILL No. 2: ELECTRICAL INSTALLATION (Continued)
DESCRIPTION
AMOUNT BROUGHT FORWARD FROM PREVIOUS PAGE
KIOSK
N/A
MAIN DISTRIBUTION BOARD IN PLANTROOM
N/A
SLEEVES
Supply and install the following PVC Sleeves.
110mm diameter
Slow bends
TRENCHING
Cutting of concrete pavement 300mm wide and breaking up of concrete. Allow for removal
of rubble from site and reinstating pavement once cable is installed.
CIRCUIT BREAKERS - Supply and install
160 amp Triple pole 20 kA installed in minisub
Excavation and backfilling of 300 mm wide by 600 mm deep cable trenches in pickable
soil.
Earth
Soft Rock
Hard rock
Galvanized Metis Steel Rail
DRAWINGS
The supply of 3 sets of A3 installed drawings and certificate of compliance to cover all the
electrical work carried out.
ITEM UNIT QTY RATE AMOUNT
1
Item 1
2
Item 1
3
Item 1
4
Item 1
6
Item 1
7
Item 1
8
Item 1
R
Cummings (or similar approved) 120 kVA, 3 phase Diesel driven outdoor Generator set
complete with diesel tank, batteries, powder coated mild steel canopy, and all other
material required for full operation of the generator set.
( Including first fill of all lubrication, oils and diesel )
B - BILL No. 3: MECHANICAL INSTALLATION
DESCRIPTION
EMERGENCY STANDBY GENERATOR
Supply, Deliver and Install of standby
Generator complete as specified for the following size:
Construct standard concrete plinth as specified by Engineer
DUMMY LOAD AND CONTROL SYSTEM
Supply and install a dummy load control system (rated as per generator suppliers
specifications) ensuring the machine always runs under load conditions as per
specification
Dummy Load
WARNING NOTICES
Supply and Install warning notices on the container
Supply & installation of Control panel as per specification
Generator Control panel with Lovato or Deep See controller, complete with cabling,
protection circuit breakers and change over as per schematic - C2206 SLD E1 001 R1
EXHAUST SILENCER - Sound Attenuated
Design supply and install the stainless steel exhaust silencer for the generator, including
lagging
CONCRETE PLINTH
as specified.
Set of Warning Notices as per SANS and OHS specifications.
MANUALS
Compilation of Maintenance, operational and technical
Manuals to the client satisfaction
Supply manuals
AMOUNT CARRIED FORWARD
Mount or secure the generator set onto the concrete plinth as specified.
DISTRIBUTION BOARDS & SWITCH GEAR
B - BILL No. 3: MECHANICAL INSTALLATION (Continued)
ITEM UNIT QTY RATE AMOUNT
R
9
Item 1
Item 1
10
Item 1
11
Item 8
m 50
R
DESCRIPTION
AMOUNT BROUGHT FORWARD FROM PREVIOUS PAGE
TEST AND COMMISSION
Test and Commission to deliver a fully operational
generating set to the client and engineers satisfaction:
At the suppliers premises, prior to delivery to site
On site after completion of the installation
MAINTENANCE
12 Month maintenance as per the specification.
Total Carried to Summary OF Bills of Quantities
Supply and install signal cable to MCC control plant after fail generator engine start,
complete with all fittings and terminations as per specification.
Key alike padlocks with 3 spare keys
OTHER
BRAAMFONTEIN NHLS LABORATORY
SUMMARY OF BILLS OF QUANTITIES
TOTAL
1 R NIL
2 R
3 R
R
__________________________________ ___________________
TENDERER’S SIGNATURE DATE
ADDRESS: __________________________________
__________________________________
__________________________________
__________________________________
TOTAL FOR GENERATOR INSTALLATION (Excl. VAT) TO BE CARRIED FORWARD TO PART 1 : TENDER PRICE
BREAKDOWN SCHEDULE : SCHEDULE 4
SUPPLY, DELIVERY AND INSTALLATION OF EMERGENCY GENERATOR SET COMPLETE WITH AUTOMATIC MAINS FAILURE PANEL
DESCRIPTION
BILL NO: 01 PREAMBLE TO BILL OF QUANTITIES
BILL NO: 02 ELECTRICAL INSTALLATION
BILL NO: 03 MECHANICAL INSTALLATION
PART 4 UPS INSTALLATION PROJECT SPECIFICATION
PART 4 UPS INSTALLATION PROJECT SPECIFICATION INDEX ITEM DESCRIPTION PAGE NO.
1.0 SITE 3
2.0 VISIT TO SITE 3
3.0 BILLS OF QUANTITIES 3
4.0 SCOPE OF CONTRACT 3
5.0 GENERAL UPS INSTALLATION 3
6.0 INSPECTION AND TESTING 10
7.0 TESTING AND COMMISSIONING DOCUMENTATION 11
8.0 COMPLETION OF INSTALLATION 11
9.0 AS BUILT DRAWINGS 11
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PROJECT SPECIFICATION
1.0 SITE
The site is located on the corner of Hospital street and De Korte street, Braamfontein,Johannesburg 2017. 2.0 VISIT TO SITE
Tenderers shall acquaint themselves with local site conditions such as access to the site, size and type of site, type of ground, supply of labour, workshop space, transport, loading and unloading facilities, scaffolding, tackle and tools needed for the erection of the installation. Additional claims by the Sub-Contractor, which may arise from ignorance of the site conditions, will not be considered and Tenderers are required to visit and inspect the site in the company of the engineer for a formal site visit. Refer to the principal contract for the date of the site inspection.
3.0 BILLS OF QUANTITIES
Included in this document is a bill of quantities for every type of operation which may occur during the execution of the electrical installation. As part of their submission, tenderers must complete this bill of quantities.
The rates supplied in this bill shall be fixed for the duration of the contract and be nett, excluding VAT. The rates for the supply and installation shall be inclusive of small items, such as screws, washers, etc.
These rates shall be used in the adjudication of the electrical tenders.
4.0 SCOPE OF CONTRACT
The following scope of work is included in this contract:
a) Supply and Install new 100kVA Industrial type Uninterruptable Power Supply complete with 30 minutes standby battery power, alarm cables and connectors to new DB and all required controllers.
b) Termination onto 200A Heavy current industrial socket outlet on load cable and female 200A heavy current industrial coupler on supply cable.
c) Set up required load requirements and warning requirements. d) Deliver and install Uninterruptable Power Supply at required position, sub-contractor to ensure
dimension of the available room is sufficient. e) Test and commissioning to be witnessed by Client and Engineer. f) Maintenance manuals and training to be provided the facility.
5.0 GENERAL UPS INSTALLATION
1.1 This specification covers the design, supply, delivery, installation, testing and commissioning of a continuous
duty, non-redundant 50 Hz, 100kVA, 400V, three phase, four-wire uninterruptible power supply system complete with maintenance-free 10 year lifespan sealed battery. The uninterruptible power supply system, hereafter referred to as the UPS system, shall operate in conjunction with the existing power distribution system. In the event of an emergency it shall be able to supply independently at least 30 minutes of clean and regulated uninterruptible power for Air-conditioning/HVAC equipment and other critical loads. Only”True-On-Line” technology, also called Continuous Operation with By-pass (COB), following the EN-50091 standard, are accepted.
1.2 The UPS system and all associated equipment and components shall be manufactured in accordance with the
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EN-50091 standards.
1.3 The UPS manufacturer must be ISO 9001 certified and must have a minimum of 25 years experience in the design, manufacture, and testing of UPS systems.
Tender submission requirement
2.1 The tender submission shall be in sufficient details to show compliance to the specification and shall include a full set of descriptive and technical literature on the equipment and system proposed.
2.2 The following drawings and information are to be submitted with the proposal:
a) System configuration with Single Line Diagrams. b) Functional relationship of various equipment and shall include weights dimensions and heat dissipation of
each unit. c) Layout plan of control panel, alarm panel, mimic diagram and remote monitor panel. d) A detailed description of acceptance test procedures and checklist. e) A reference list of similar systems installed.
Environmental conditions
4.1 The UPS system shall be capable of withstanding any combination of the following environment conditions in which it must operate, without mechanical or electrical damage or degradation of operating characteristics: a) Ambient temperature : 0 to 40 degrees C b) Relative Humidity : Up to 95% (non-condensing) c) Interference : The UPS equipment shall be provided with EMI/RFI suppression
following EN-50091-2
4.2 Audible Noise - Noise generated by the UPS system under any condition of normal operation shall not exceed an allowable sound pressure level of 65 dBA measured at a height of 1 metre at 1 metre from the nearest UPS cabinet surface.
System description
4.1 The UPS system shall consist of the following major equipment: a) One rectifier/charger b) One static inverter c) One no-break static transfer switch d) One maintenance by-pass switch e) One battery bank f) One main control and alarm panel complete with mimic diagram and LCD back-lit display g) One (optional) set of remote control and monitoring system for the UPS installed in any IBM compatible
PC situated up to 300 meters away without the need of modems.
4.2 The UPS system shall be able to operate in any of the following:
4.2.1 On-line Mode - During on-line operation mode, the UPS system shall be used to provide precise regulated and transient-free power to the computer equipment loads. The mains supply provides power to the rectifier/charger. The rectifier/charger shall provide regulated DC power to support the inverter and simultaneously maintain the battery in a fully charged condition. The inverter shall convert the DC power into regulated AC power for the load. A signal cable should be provided from the generator to the UPS to ensure the UPS is online during emergency generating power
4.2.2 Battery Mode - Upon failure of the mains supply, input power for the inverter shall automatically be supplied from the directly connected battery. When the mains is restored or the standby generator set supply is ready, input power for the inverter and for recharging the battery shall automatically be supplied from the rectifier/charger.
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If the input does not return, the UPS shall automatically shut itself down in an orderly manner when the discharge limit of the battery is reached.
4.2.3 By-pass Mode - Upon the failure of static inverter, the no-break static transfer switch shall be activated automatically to isolate the faulty inverter and at the same time maintain a continuous supply to the system load. The automatic transfer mode shall also operate in the event of system overloading or if irregular or undesirable output for the load is detected. In this case, the system shall automatically return to the original on-line mode operation if the disturbance is cleared.
4.2.4 Manual By-pass Mode - If the UPS system needs to be isolated for testing or removed from service for maintenance, the maintenance by-pass shall transfer the loads from inverter to the mains without interruption and vice versa. Electrical characteristics
5.1 General a. UPS Output Power Rating- 100 kVA, 3 phase, 4 wire plus earth, power factor 0,9 b. Overall Efficiency - 94% minimum at full load
5.2 Rectifier c. Input: - Voltage = 3x400V + N (+10/-20%) - Frequency = 50/60 Hz + 6% - Power Factor > 0.8 lagging
5.3 Inverter d. Output: - Voltage = 3x400V + N - Frequency = 50/60 Hz + 0,1% free running = + 4% adjustable with mains synch. e. Output voltage THD - Linear Load = < 2% - Non-linear Load = < 3% (to EN-50091) f. Phase Displacement -100% balanced load = +/-1% -100% unbalanced load = +/-2% g. Voltage Unbalance - for balanced load = +/- 1% - for unbalanced load = +/- 3% h. Voltage Transients - at 50% load step = +/- 2% - at 100% load step = +/- 3% - static 100% load = +/- 1% - by mains recovery = +/- 1% i. Recovery Time = 20 msec. to + 1% l. Inverter Overload Capability = 125% for 10 min. = 150% for 30 sec. k. Crest Factor > 3:1 (according to EN-50091) Rectifier/charger
6.1 General - The rectifier/charger shall consist of a 6-pulse SCR bridge, which converts the 3-phase utility voltage into a controlled and regulated DC voltage, in order to supply power to the inverter, and to simultaneously charge the battery
6.2 Capacity - The rectifier/charger shall have sufficient capacity to support a fully loaded inverter and at the same
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time maintain the battery in a fully charged condition. If the battery is fully discharged, the rectifier/charger shall recharge the battery to 95% of its fully charged condition preferably within twelve (12) hours and at the same time supplying full load current to the system. Otherwise the UPS supplier shall specify the charging time required.
The Rectifier shall be designed to ensure the relevant HVAC equipment does not draw its load from the UPS.
6.3 Walk-in - The rectifier/charger must contain a timed walk-in circuit to limit the inrush current. The allowable
initial inrush surge and the walk-in time should be adjustable and not exceed 30 sec.
6.4 Current and Voltage Limit - The rectifier/charger output current and voltage shall be limit to the battery supplier's recommendation.
6.5 Temperature Compensated Charging - The rectifier/charger output voltage shall be automatically adjusted in
proportion to the ambient temperature of the battery as per the battery supplier's recommendation to avoid over-charging.
Inverter
7.1 General - The conversion of DC to AC must be accomplished by power transistors of the IGBT type. Failure of any components or power stage shall not interrupt the AC output instead it shall disconnect itself from the configuration while transferring the load to the static transfer switch and then activate an alarm.
7.2 Standard Control Battery - A control battery shall be provided to furnish logic power, which is independent of
the inverter input or output power. The battery shall provide the power required to operate the inverter logic until the load is transferred to the alternate source and the inverter is shut down in an orderly manner in the event of a failure of the logic solid- state power supply. In addition, the battery shall provide power to the alarm system to maintain alarm indicators after a UPS failure and shutdown.
7.3 Output - The inverter output waveform shall be controlled by microprocessor-based software (software
generated sine wave) to ensure that the voltage THD is being limited especially for non-linear loads. 7.4 The waveform shall be fed through a filter circuit and protected by fast fuses. The inverter shall be able to
handle short-circuit conditions without any damage.
7.5 Neutral - The neutral of the inverter output shall be electrically isolated from the UPS system chassis.
7.6 Frequency Control - The output frequency of the inverter shall be controlled by an oscillator, which can be operated as a free running unit or in synchronised operation with a separate AC source.
7.7 If the external synchronising source deviates from the pre-set frequency by + 1% or 4% (selectable), the oscillator shall automatically revert to free-running, and the microprocessor controlled accuracy shall be + 0.1%.
7.8 Capacitor Discharge - Output filter capacitors shall be provided with a quick discharging circuit which shall
automatically discharge the capacitors to safe value within a short time after the shutting down of the inverter. Electronic by-pass switch
8.1 The electronic by-pass shall consist of a static SCR-switch, used to provide an uninterruptible transfer of the load to the utility in case of remarkable variation of the output voltage. The electronic by-pass shall be equipped with two contactors in series, which provide to supply the load from utility or inverter.
8.2 The electronic by-pass switch must have continuous 150% overload rating capacity. In addition the static
transfer switch shall support 200% overload for 10 minutes and 1000% overload for 10 milliseconds.
8.3 The electronic by-pass switch shall return the load automatically to the UPS when the malfunction or overload
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is cleared.
8.4 The electronic by-pass switch shall consist a pair of microprocessor controlled thyristors and a contactor in series.
8.5 The electronic by-pass switch shall be able to be activated manually by a switch/push button to affect the
transfer. The switching time from inverter to reserve (bypass) and vice-versa shall be of No-Break when synchronised.
8.6 Automatic retransfer delay time back to inverter from reserve after a transfer from inverter to reserve shall be
10 seconds.
8.7 The number of automatic transfer/re-transfer from by-pass to inverter when the status of the inverter logic signals an alarm conditions, shall be selectable.
Maintenance by-pass
9.1 The maintenance by-pass shall be based on a pair of manually operated circuit breakers which allow the electrical isolation of the UPS from the load, while still supplying the load with power directly from the utility.
Battery / battery test
10.1 A battery shall provide the UPS system with a stored energy source. The battery shall be of a heavy-duty industrial type designed for standby power service. The cells shall be completely sealed maintenance free.
10.2 The ampere-hour rating of the battery shall be sufficient to support the inverter for the protection time of 30minutes with the inverter operating at full rated load at power factor 0.8.
10.3 Tenderer shall submit full technical data of the battery offered under the tender and shall provide calculation to show the number of cells required and their capabilities which shall match the load requirement and the charging characteristics of the UPS requirement being offered.
10.4 Tenderer shall specify the recommended voltage per cell for float charging and recharging, acceptable electrolyte specific gravity when fully charged at 25 degrees C.
10.5 The UPS must be provided with a manual and automatic battery test (pre-selectable by day of the week, time of day, date of the month). The test operates by slowly initiating a linear decrease of the rectifier output voltage. When a battery fault is detected, the rectifier voltage will return to nominal. Automatic battery testing by shutting down the rectifier is not permitted. Instrumentation
11.1 A back-lit 4 x 20 alpha-numeric characters Liquid Crystal Display (LCD), controlled by push buttons shall be provided.
11.2 The UPS system main control panel with LCD back-lit display shall include the following measurements indications: a) Rectifier: input voltage, input frequency, number of mains failure b) Battery : voltage, temperature, charge/discharge current in Amperes, charge level %, remaining
autonomy time c) Inverter: output voltage, output frequency, temperature, operating hours d) By-pass: input voltage, input frequency, number of mains failure e) Load :load level in %, load level in kVA, load current/phase in A, load current/phase in % f) General: UPS model, UPS power rating, operating hours, serial number, software version, number of
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overload occurrences, IEM mode settings, IEM mode mains statistics. (IEM mode 10-40kVA only).
11.3 The UPS system main control panel with LCD back-lit display shall include the following events indications
with date and time: a) Rectifier: mains rectifier OK, rectifier ON/OFF. b) Battery: start battery test, end battery test, no conditions for battery test. c) Inverter: inverter cannot be switched ON/OFF, inverter ON/OFF. d) By-pass: mains by-pass OK, by-pass power insufficient, by-pass locked, by-pass free. e) Load : load-OFF, multiple load transfer, load on by-pass/inverter, no more overload condition. f) General: maintenance by-pass ON/OFF, inverter and mains synchronised/not synchronised, input circuit
breakers open/closed.
11.4 On the system alarm panel, a common audible alarm and the respective indicating LED’s shall be initiated
when any of the following conditions are present: a. Rectifier: mains out of tolerance; control logic failure. b. Battery: low voltage; high voltage; earth fault; contactor closing or opening failure; insufficient power. c. Inverter: fuse failure; contactor closing or opening failure; voltage out of tolerance; output power
insufficient; overload. d. By-pass: mains out of tolerance; contactor closing or opening failure. e. Load: overload; load locked on inverter; load locked on by-pass. f. General: load off for overload; battery low and over-temperature conditions; inverter and mains not
synchronised; UPS overload.
11.5 The UPS, through the LCD, must be able to store up to 256 alarms or events with date and time.
11.6 Mimic Panel - A mimic panel shall incorporating LED indicators depicting the complete single line diagram of
the UPS system shall be silk-screened to display the following: a) A synoptic diagram of the UPS representing actual operational status with integrated LED’s and power
flow indications. b) Emergency shutdown LOAD OFF push button with protective cover. c) Signal SERVICE CHECK (LED) to indicate that maintenance is required. d) COMMON ALARM, visual signal (LED) and acoustic signal (internal buzzer). e) Signal STOP OPERATION (LED), visual and acoustic warning approximately 3 minutes (programmable)
before complete automatic load disconnection (for example when the battery is at minimum voltage or inverter is over-temperature).
f) LED indication for the battery and load level. g) Command button keys for INVERTER ON and INVERTER OFF. h) Command button key for LED functionality test. i) Command button key (MUTE) to reset general alarms and buzzer. Tenderer shall provide detailed information for the above-mentioned together with their tender submission. Mechanical Design
12.1 Enclosure - The UPS system shall be housed in free standing steel cabinet constructed and painted
according to ISO 2813/2360/2409/1519.
12.2 Colour - The UPS cabinet colour shall be RAL 1013 (pearl-white)
12.3 Ventilation - Forced air-cooling shall be provided to ensure that all components are operated within
specifications with air entry in the base and exit in the top. The air volume and fans speed must be microprocessor-based controlled in relation to the inverter bridge heat-sink temperature.
12.4 Cable Entry - Input to the system and outgoing cables shall be from the bottom front or top/bottom rear of
the cabinet.
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12.5 Modular Construction - The UPS system shall be modular in construction for ease of maintenance and to
minimise downtime.
12.6 Power Connections - Adequate space for termination shall be provided for incoming and outgoing cables.
The cables for interconnecting the UPS and battery cubicles shall be supplied for side by side installation.
12.7 Personal Safety - High voltage, low voltage and DC section of the system shall be adequately separated to
ensure safety during maintenance and testing. The equipment shall meet the requirements of protection index IP 20. Acceptance
13.1 The tenderer shall submit a detailed acceptance procedures and checklist which shall be designed to verify
the full compliance of the installed system with this specification.
13.2 The acceptance test shall be carried out by the contractor's engineer and witnessed by the end-user's
Project Engineer.
13.3 3 copies of the test report and commissioning certificate stating that the system has been installed and
commissioned to the requirement of the specification shall be submitted to the end-user on handing over the commissioned system. Documentation
14.1 All documentation shall be written in good, simple and concise English using accepted technical terms,
symbols and nomenclatures. For submission, all documentation shall be bounded with hard covers.
14.2 The document shall be updated regularly as the installation progresses. All changes in the installation
layout, wiring, cabling and design shall be incorporated in its final edition. _____ copies of this final edition shall be handed over to end-user upon commissioning of the system.
14.3 The final edition of the hand-over documents shall cover design, installation, commissioning, operation and
maintenance aspects of the system.
14.4 One set of basic consumable spare parts shall be supplied under the contract.
Maintenance
15.1 The tenderer shall be responsible for the maintenance of the system after the expiring of the warranty
period. In the tender submission, the tenderer shall include a maintenance agreement for the subsequent maintenance of the system for consideration by the end-user.
15.2 The agreement shall include a fixed sum proposed for 3 years to perform regular testing and up-keeping of
the system.
15.3 The tenderer shall submit a checklist on the activities to be carried out for the system regular maintenance.
15.4 The tenderer shall provide evidence and undertake that round the clock on-call service is available to attend
to system failure. Options for UPS Input Configurations
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16.1 Filter for 5th Harmonic reduces input current THD to 10% and improves input power factor to approximately
0.95 at full load. The filter must never present a capacitive load to the mains.
16.2 Distortion Control Unit (DCU) stepped filter for 5th, 7th, 11th and 13th reduces reflected current harmonics to a
value of less than 7% and improves input power factor to 0.98 at full load. The filter must never present a capacitive load to the mains.
16.3 Input isolation transformer for galvanic separation of UPS from mains/utility supply to improve noise
immunity but primarily as a safety devise to prevent back-feed of DC voltage onto the mains. Options for Communications and Monitoring
17.1 Remote Monitor and Control A remote control and status panel of the UPS shall be provided that allows
complete control and operation of the UPS from a remote location connected to the UPS via RS232 or RS422.
17.2 Remote Signalling System consists of a remote mimic panel with LED indicators and audible alarm.
17.3 Potential Free Contacts must be available on the UPS to indicate the following signals: audible alarm active;
general alarm; load on mains; stop operation (battery low); load on inverter; mains failure; as well as 4 customer selectable alarms from a list of alarm/status conditions of the UPS including: over-temperature; battery fault; battery earth fault; bypass locked; battery discharge; boost charge; rectifier on; inverter on; manual bypass on; etc.
17.4 Input Connections for customer provided signals must be available for ”generator on” (reduces battery
charging current during mains failures) and ”emergency power off” (to shutdown UPS and load in the event of an emergency).
17.5 Remote Software Control allows remote monitoring, management and control of up to 240 numbers of UPS
of different capacity and at different locations by means of modems from one central location. The software shall allow the user to fully control the operational parameters of the UPS (e.g.: Rectifier and Inverter ON/OFF; etc.) from the PC. The system shall also allow the manufacturer or its nearest regional service centre to gain access to the UPS installed at the user's premises for remote on-line diagnostic and operational purpose.
17.6 SNMP adapter It shall be possible to connect the UPS to a TCP/IP network using SNMP (simple network
management protocol) using the international standard UPS MIB.
17.7 UPS Data Protection Software The UPS shall have available data protection software compatible with
Windows/95, Windows/98, Windows/NT, UNIX, Novell, OS/2 and other common operating systems.
17.8 Internet Information and Alarm transmitting The UPS shall be able to communicate relevant data and alarms
via the Internet to multiple addresses as E-mail, FAX and SMS. The remote access to the UPS shall be protected.
6.0 INSPECTION AND TESTING On completion of the entire installation or any particular section thereof, as may be decided by the Engineer, tests shall be carried out in full accordance with the current edition of SANS 10142-1, the “Code of Practice for the Wiring of Premises”, in the presence of the Engineer or his authorized Representative. Note:
1. All instrumentation necessary for testing shall be provided by the Sub-contractor. 2. The results of the above tests must be clearly recorded, signed and handed to the Engineer.
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3. Once the Engineer has inspected the complete installation and satisfied himself that all testing has been completed and the Sub-Contract is complete in all respects, may the Engineer be approached in writing with the above documentation with a view to arranging a hand-over date.
4. On completion of the Contract, the Contractor shall provide the Engineer with a complete and signed Certificate of Compliance for Electrical Installations as required by the Occupational Health and Safety Act as amended.
7.0 TESTING AND COMMISSIONING DOCUMENTATION
On completion of the Electrical installation and after testing and commissioning, a set of documents shall be compiled and presented to the Engineer. This set shall include the following: 1. Completed set of workshop drawings. 2. Completed set of test and commissioning sheets. 3. Set of schematic wiring and function diagrams 4. Operating and maintenance instructions on all electrical equipment.
Testing and commissioning of the UPS installation shall be in accordance with the local DPW requirements.
8.0 COMPLETION OF INSTALLATION
Before the commencement of any tests or commissioning procedures, the Contractor is to ensure that all nuts and bolts are securely fastened, and that paintwork on all items supplied has been touched up where damage has occurred. The UPS shall be formally handed over to the facility, who will assume responsibility for maintenance of the UPS.
9.0 AS BUILT DRAWINGS
The Contractor shall submit to the Engineer a complete set of accurately marked-up of all services installed at completion. The drawings shall be a hard copy of each drawing shall be submitted as well as a compact disk containing relevant drawing titles.
C - Bill No. 1: UPS Installation
Item Description Unit QTY Supply Install Amount
Supply & Install the following equipment including all connectors, terminal screws,
alarm cables complete with terminals and sockets:
1,1 UPS
1.1.1Gutor/Schneider (or similar approved) 100kVA 3Ø - 3 Ø
industrial type UPS, as specifiedNo 1 -R
1.1.2
Terminate load cable onto 200A heavy current 5 pin industrial
female coupler and supply incomer onto 200A heavy current 5
pin industrial male socket outlet
No 1 -R
1.1.3Supply 1mm² 7 core alarm cable from UPS to DB-LAB/UPS and
terminate onto DB alarm ports.m 20 -R
1.1.4Supply 2,5mm² 7 core signal cable from generator control panel
to UPS control panel. m 55 -R
1.1.5Provide all required sockets and ports to be connected onto DB-
LAB/UPS from UPS (See schematic C2206E1 SLD 002)No 1 -R
1,2 Sundries
1.2.1 Provide additional airflow/louvers if required Sum 1 -R
1.2.2 Any additional items to conform to specification : Sum 1 -R
Please list them:
Total for Bill 1 carried forward to summary page: -R
SUMMARY OF BILLS OF QUANTITIES
TOTAL
1 BILL NO: 01 PREAMBLE TO BILL OF QUANTITIES R NIL
2 BILL NO: 02 UPS INSTALLATION -R
__________________________________
TENDERER’S SIGNATURE
ADDRESS: __________________________________
__________________________________
__________________________________
__________________________________
Description
TOTAL FOR UPS INSTALLATION (Excl. VAT) TO BE CARRIED FORWARD TO PART 1 - TENDER PRICE
BREAKDOWN SCHEDULE : SCHEDULE 4
PART 6 DECLARATION FOR COST CONTROL FOR THE ELECTRICAL WORKS
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NHLS Aerosol Laboratory Braamfontein: Cost Control
Part 6 : Page No.2
DECLARATION FOR COST CONTROL The tenderer’s attention is directed to the following cost control procedures which is to be implemented and strictly adhered to on this contract.
1. Tenderer’s are advised to take cognisance of the Notes to Tenderer’s and Preliminaries Applicable to the Main Contractor, as no claims arising out of his failure to comply with aforesaid will be entertained.
2. The successful tenderer will be required to notify the engineer, timeously (within seven (7) calendar
days), of any or all variations, with their associated cost implications. VARIATIONS NOT APPROVED BY THE ENGINEER WILL NOT BE PAID FOR.
3. Where applicable, variation meetings will be held at stipulated dates (preferably on a monthly basis) in
order to assess the nature and implications of any variations. (Dates and times will be advised by the quantity surveyor).
4. Valuation of payment claims as submitted to the main contractor or submitted by the main contractor,
shall be broken down in sufficient detail to assist the quantity surveyor in the evaluation thereof. 5. The successful tenderer will be required to submit a projected Final Account on a monthly basis (with
his payment claim) reflecting variations, if any, at that particular stage of the contract.
DECLARATION I/We …………………………………….the undersigned of ………………………………… in my / our capacity as ………………………………...….. do hereby accept to implement the aforesaid cost control procedures to ensure budgetary control. Signature: ………………………………………… Date: ……………………………………………… This declaration is to be signed and submitted together with the Form of Tender. Failure to do so will render the tender incomplete and the tenderer will be disqualified.