nioh specification for construction of a … plinth for the chiller e. new plinth for the generator...

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

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PROJECT SPECIFICATION






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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






17

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.






18

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.






19

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






20

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






21

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.






22

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:






23

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.






24

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.






25

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






26

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.


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.






27


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






28

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






29

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.






30

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.






31

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






32

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.






33

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






34

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.






35

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.






36

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






37

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.






38

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).






39

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)


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


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

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


Item Description Sub-Total

TOTAL FOR SCHEDULE NO. 1




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


NHLS Aerosol Laboratory Braamfontein Project Specification Part 2 Page No.3


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.


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



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.



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



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



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.



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



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.



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



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



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.



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.



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.



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.



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.



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.



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.



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.



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.



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:



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.



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.



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



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.



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



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.



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


NHLS Aerosol Laboratory Braamfontein: Bills of Quantities

: 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

Page 50

WCS 045933


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

Page 51

WCS 045933


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



Total for A - Bill No. 2 Carried forward to summary page -R

Page 52

WCS 045933


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

Page 53

WCS 045933


A - ELECTRICAL INSTALLATION (GENERAL)


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.

Page 54

WCS 045933


A - BILL No. 3 : ELECTRICAL INSTALLATION - SMALL POWER


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


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


A - BILL No.4 : ELECTRICAL INSTALLATION - LIGHTING


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


Page 57

WCS 045933


A - BILL No.5 : ELECTRICAL INSTALLATION - Electronic Services


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 %


Page 58

WCS 045933


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



INDEX ITEM DESCRIPTION PAGE NO.

1.0 SITE 3

2.0 VISIT TO SITE 3



5.0 PROGRAMME 9

6.0 WORKMANSHIP 9

7.0 QUALITY OF MATERIAL 9





12.0 SCHEDULES OF TECHNICAL INFORMATION 11




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.


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.





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



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.



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.



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.



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)



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)



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



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.



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.



Testing and commissioning of the generator installation shall be in accordance with the local DPW requirements.


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.


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



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



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


3. Is board floor mounted?

4. Finish of board

5. Make of volt, amp, and frequency meters



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



1. Maker’s Name


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


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.


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)


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



5.0 GENERAL UPS INSTALLATION 3








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.


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.





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



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.



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



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



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



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.



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



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.



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.



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.


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.


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


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.